Erstellungsdatum: 12.06.

2007
Letzte Änderung: 09.07.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3.fm

September 2007

DVS – DEUTSCHER VERBAND Welding of thermoplastics

FÜR SCHWEISSEN UND
Hot-gas string-bead welding and hot-gas welding
with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Methods, requirements
DVS 2207-3

R&D INTAKE MANIFOLDS

Translation of the German version from April 2005

Contents: welding of semi-finished thermoplastic products in tank, process

equipment and pipeline manufacture. It describes the various
1 Applicability methods, shows the method limitations and defines the quality
2 Materials assurance requirements.
3 General description of the method
3.1 Hot-gas welding with torch separate from filler rod (WF) Hot gas welding is mainly used for welding material thicknesses
3.2 Hot-gas string-bead welding (WZ) between 2 and 10 mm. Larger thicknesses are generally hot-gas
4 Device types extrusion welded according to DVS 2207-4. Special applications,
5 Constructional design, weld shapes and weld structure such as welding of waterproof sheeting, are described in
6 Requirements DVS 2225-1 and 2225-4; welding of PE pipe jackets is described
6.1 Requirements for the materials and their weldability in DVS 2207-5.
6.2 Quality requirements for welding joints
6.3 Requirements for welding tools and accessories
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

6.4 Requirements for welders 2 Materials

7 Commissioning welding equipment and setting the welding
parameters
8 Preparation for welding This technical code applies for the materials stated in DVS 2207-3
8.1 Equipment Supplement 1. The technical code can be applied in principle to
8.2 Protection against environmental influences other materials and material modifications (e.g. electrically
9 Welding conducting). Supplementary notes from the semi-finished
9.1 Preparing the joining surfaces and the welding filler products manufacturer are to be observed.
9.2 Tacking
9.3 Hot-gas welding with torch separate from filler rod (WF)
9.4 Hot-gas string-bead welding (WZ) 3 General description of the method
9.5 Mechanical reworking of the weld
9.6 Thermal reworking A welding filler (for example round or section rod) is used in hot-
9.7 Welding record sheet gas string-bead welding and hot-gas welding with torch separate
10 Testing the welded joints from filler rod. The joining surfaces of the base material and the
11 Safety instructions welding filler are plasticized with hot gas, usually air (require-
12 Other applicable standards and technical codes ments – see DVS 2207-3 Supplement 2), and joined under
Appendix 1: Brief instructions for welding pressure.
Appendix 2: Welding record sheet
3.1 Hot-gas welding with torch separate from filler rod (WF)
1 Applicability
The base material and the welding filler are heated with a stream
This technical code applies for hot-gas welding with torch of hot gas directed to the joining surfaces by means of the round
separate from filler rod (WF) and hot-gas string-bead (WZ) nozzle fitted on the welding tool, Figure 1.

Figure 1. Hot-gas welding with torch separate from filler rod.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group ″Joining of Plastics″

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

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Page 2 to DVS 2207-3
R&D INTAKE MANIFOLDS
Figure 2. Hot-gas string-bead (rod) welding.
The welding tool is passed along the welding joint in continuous
motion. The plasticized welding rod, positioned by hand is placed
in the welding joint with the application of joining pressure. The
main areas of application are hard to access places, as well as
the weld root, especially in the case of PVC.
3.2 Hot-gas string-bead welding (WZ)
In this method, the welding filler is fed through a channel located
in the nozzle into the joining zone. The nozzle channel must
match the shape of the welding filler.
The welding filler and the base material are evenly pre-heated
and plasticized by directing the stream of hot gas and as a result
of the shape of the draw nozzle. The required joining pressure is
applied via a beak shaped tip on the end of the nozzle (nozzle
shoe). When handled correctly, welding is more continuous, even
and faster than with hot-gas welding with torch separate from
filler rod.
Hot-gas string-bead welding is therefore preferable to hot-gas
welding with torch separate from filler rod. However, it is not
always practicable in inaccessible places.
4 Device types
Welding tools (torches) consist of an electrical lead, welding gas
supply, handle, heating element including regulator or controller,
as well as replaceable nozzle. The welding gas is usually heated
with an electrical resistance heater. Torches are distinguished
between those with an external welding gas supply and those
with an integrated blower, as well as between electronically
regulated and electronically controlled torches.
– Torches with an external welding gas supply require an additio-
nal blower, compressed gas bottles or a compressed air con-
nection for their gas supply. This also enables the use of gases
other than air (for example nitrogen in the case of oxidation-
sensitive materials). They are better suited for prolonged use
on account of their lightweight construction, Fig. 3 a.
– As a result of their high weight, torches with integrated blowers
are mostly used for brief welding jobs, for example on-site wel-
ding, Fig. 3 b.
– Regulated torches include incorporated welding gas tempera-
ture measurement with regulating electronics integrated into
the tool. The tools allow a highly consistent welding gas tem-
perature irrespective of environmental influences, fluctuation in
air flow rates and changes in voltage. This is normally indica-
ted on a display with target and actual values.
– Controlled torches do not include internal temperature com-
pensation. The actual temperature is subject to fluctuations of
the air flow applied and of the supply voltage.
344
a)
b)
Figure 3. Hot gas welding torch;
a) Torch with external gas supply,
b) Torch with internal blower.
5 Constructional design, weld shapes and weld structure
DVS 2205 applies to the construction of the components.
The constructional design and dimensioning of the welds is
subject to DVS 2205-3. The terminology, drawing and symbolic
representation of the welds is subject to DIN EN 22553.
Special attention should be paid that:
– Crossing welds must be avoided.
– The separation of welds must be approx. 3x the width of the
covering layer, however at least 30 mm.
– The different thicknesses of the connection ends for butt joints
must be matched with the thickness of the workpiece (DVS
2205).
– In the case of accessibility from only one side only, a weld
shape should be chosen which ensures that the cross-section
of the respective thinner joining part can be completely con-
nected (for example for a T-butt with single-bevel weld).
– It must be ensured that the joining surfaces allow for proper
handling of the welding torch.
The most important seam geometries are V butt, double-V butt,
single-bevel, double-bevel weld.
Welding fillers can be round or profile rods according to DVS
2211. Round rods are usually multi-layer welded depending on
the weld cross-section. Profile rods are usually processed in a
single layer. This requires adaptation of the seam geometry to
the section in accordance with the welding filler manufacturer’s
specifications.
Table 1 shows the common materials and seam opening angles
for V and double-V welds. The angles 45° and 90° are common
for fillet welds, Fig. 4.
 Page 3 to DVS 2207-3

R&D INTAKE MANIFOLDS

0 – 2 mm
0 – 2 mm

a) V-weld on butt joint – b) V-weld on butt joint – c) Double V-weld

without backing with backing at a butt joint
0 – 2 mm

d) Single-bevel weld with e) Double-bevel weld at T-joint f) Double fillet weld

fillet weld at T-Joint
Figure 4. Common welding geometries.

Table 1. Materials and seam opening angles for V and double-V welds .
Material Weld opening angle α
PE- HD(1), PP(2), PVC, PVC- C, PVDF, E/CTFE 60°-70°
MFA, FEP, PFA 0°-30° (dependent on material thickness)
(1) PE 63, PE 80, PE 100 ; (2) PP- H, PP- B, PP- R

Table 2. Examples for the weld structure dependent upon the material thickness with an opening angle of 60°.

Base material thickness Welding rod (round)

in mm Number x diameter [mm]
V-weld 2 1x4
3 3x3
4 1x3+2x4
5 6x3
if possible, additionally with
backing (7) in each case

4 per side: 1 x 4
5 per side: 3 x 3
6 per side: 3 x 3
8 per side: 1 x 3 + 2 x 4
10 per side: 6 x 3 or
per side: 1 x 3 + 3 x 4

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R&D INTAKE MANIFOLDS
welded root finished weld
Figure 5. Weld structure with a V-weld (without backing).
The layer structure is usually produced according to Table 2 and
Fig. 5. The layer structure is to be adapted for other opening
angles and weld geometries. If section rods or welding tapes are
used, the seam geometry and welding nozzles must be adapted
to the geometry of the welding filler.
The weld must be filled completely and free of occlusions and
must show a weld protrusion according to DVS 2202-1. The
numbering of the individual rods in the table shows the
recommended welding sequence.
6 Requirements
6.1 Requirements for the materials and their weldability
Semi-finished products and welding fillers must be suitable for
hot gas welding. For welding joints to be compliant with DVS
2203, a welding filler should be used which is the same as the
base material, or at least of the same type.
The melt index is used as a characteristic parameter for
weldability in the case of partially crystalline materials, such as
PE, PP, and PVDF. If the melt index values (MFR values) of the
welding components lie within the permissible meld index range
of DVS 2207-1, -11, -15, weldability can generally be assumed. If
two semi-finished products of different MFR groups from this
range are to be welded together, a welding filler is to be selected
whose MFR value lies between those of the semi-finished
products combination. In the case of PE-HD, PP and PVDF, the
instructions from the applicable technical codes DVS 2207-1,
2207-11 and 2207-15 are to be observed. If the melt index lies
outside the permissible range in the stated technical codes,
weldability is to be ascertained with tensile creep testing
according to DVS 2203-4.
For amorphous materials (such as PVC): Only semi-finished
products of the same moulding compound are weldable.
The semi-finished products and welding fillers must be labelled
accordingly and unambiguously (on the packaging for welding
fillers).
Only semi-finished products with defined quality specifications
should be welded (for example, test report in accordance with EN
10204).
The welding fillers must comply with the specifications of DVS
2211 as well as EN 12943.
The base and filling materials must be in perfect condition for
processing, dry and clean.
If there is any doubt as to the homogeneity of the semi-finished
products and/or the welding filler, for example, the absence of
labelling or if material changes are of a concern as a result of
– improper storage,
– low joining component temperatures,
– soiling
– aging,
– operational influences (media, temperatures)
the welding compatibility is to be ascertained with testing on
sample welds.
346
The nature and scope of testing are to be agreed upon. Relevant
references are given in technical codes DVS 2203-1 and 2201-2.
6.2 Quality requirements for welding joints
If the welds are produced according to this technical code, the
minimum weld quality requirements specified in DVS 2203-1
(welding factors, bending angle/distance) should be safely
achieved.
The contractor and manufacturer should agree upon and define
the specifications for the component and the welding joints in
respect of the statutory requirements for the respective
application (Federal Water Management Act (WHG), European
Pressure Equipment Directive) and the required dimensioning.
References and criteria for the definition of quality are included in
DVS 2202-1.
The required quality should be verified on test welds if necessary.
This particularly applies for materials for which no specifications
are stated in the aforementioned technical codes (for example
PFA, FEP, MFA, PVC-C etc.).
6.3 Requirements for welding torches and accessories
Welding torches must be CE compliant, safe, functional and
suitable for the welding task. This also applies for accessories,
such as nozzles, temperature probes etc.
Special requirements for the equipment are described in
Supplement 2 of this technical code.
6.4 Requirements for welders
Hot gas welding is a welding technique demanding extensive
knowledge of the materials to be welded and the operation of
equipment, as well as a high level of workmanship skills.
The welder must have passed an examination corresponding to
DVS 2212-1 and be in possession of a valid examination
certificate.
Welding of special materials (for instance FEP, PFA, MFA, E/
CTFE...) is subject to requirements equivalent to or proof of
suitability along the technical codes of DVS 2212.
7 Set-up of welding equipment and setting the welding
parameters
Set-up and setting takes place according to the operating in-
structions of the equipment manufacturer in association with the
welding parameter recommendations specified in Supplement 1
and possibly with the specifications from the raw material or
semi-finished products manufacturer. On the draw nozzles, the
nozzle shoe and the air- and material channels are to be cleaned,
for example with a brass brush prior to use or when the welding
filler is changed and possibly when welding is interrupted. The
nozzle surfaces must not be damaged.
The temperature of the hot gas is to be checked before starting
welding. The measurement is made with a suitable quick display
temperature meter (with a thermo-element of 1 – 1.5 mm diame-
ter) approx. 5 mm inside the nozzle, in the centre for round
nozzles, at the main nozzle aperture for draw nozzles. Air flow
measurement is performed at the point of entry into the welding
equipment using a flow meter (see Supplement 2).
The welding torch should be in operation at least 15 min. prior to
commencing welding and checking the parameters.
Repeated checks are recommended in the case of prolonged
welding jobs or after interruption of work.
The welder must establish the appropriate welding speed and
pressure with practice, and carry out regular checks. The welding
pressure required can, for example, be checked by test welding
on a platform balance.
All measurements must be carried out regularly with calibrated
and tested measuring equipment according to Supplement 2 and

must be documented (Appendix 2). The temperature meters
used should have a maximum deviation in their working range of
± 3 K.
R&D INTAKE MANIFOLDS
8 Preparation for welding
The weld edges of the joining surfaces are prepared according to
Section 5. It must be ensured that adequate accessibility to the
welding equipment to the joining surfaces is achieved. Problems
experienced by the welder as a result of the welding force applied
by the welder should be avoided or minimised. The welder
should not be hindered in the necessary advancement of the
connection cables, hoses, and the welding filler.
8.1 Equipment
The following equipment represents the minimum requirement for
carrying out professional welding:
– Hot gas device in accordance with this technical code and
Supplement 2
– Flowmeter for welding gas
– Fast display, digital temperature meter
– Suitable measuring equipment to check displacement / diame-
ter / thickness
– Suitable equipment storage facilities
– Scraper, retractable blade, nozzle brush, wire cutting pliers or
similar
– Table of welding parameter acc. to Supplement 1 and/or in-
structions from the semi-finished products manufacturer
– Welding record sheet acc. to Appendix 2
– Personal protective equipment
– Dust protection for welding filler
– Adequate illumination
– Protection against weather as required
– Special cleaner as required (non-swelling, dissolving or contai-
ning fat), lint-free cloths
8.2 Protection against environmental influences
The environmental conditions can have a significant effect on the
welding process and therefore the quality of the joint. The
following points should therefore be observed:
– The welding area should be protected against the weather
conditions (e.g. moisture, wind, draughts and temperatures be-
low + 5 °C).
– If the appropriate measures (for example preheating, enclos-
ure in a tent, heating) ensure that an adequate temperature of
the semi-finished products can be maintained for welding, wel-
ding can be carried out at any outside temperature provided
the welder’s manual skill is not impaired. It may be required to
produce test welds under the prevailing conditions as additio-
nal verification.
– If the joining parts are of an uneven temperature, for example
due to sunshine incident on one side, different storage conditi-
ons etc., the temperature must be equilibrated prior to welding.
9 Welding
9.1 Preparing the joining surfaces and the welding filler
The joining surfaces must not be damaged, oxidized or soiled.
They and the adjacent edges must therefore be mechanically
treated prior to welding.
Mechanical cutting tools, such as scrapers, retractable blades,
mills and drills are suitable for removal. Grinding tools are only
permissible if soiling, through the use of grinding equipment and
overheating of the surface, can be avoided.
Page 5 to DVS 2207-3
Especially in the case of joining parts subject to prolonged
exposure to UV or media, the damaged layer can be so deep that
it is necessary, after mechanical processing, to check the
residual wall thickness taking into account the static
requirements.
For the materials PVC, PP, PE and PVDF, the welding filler must
be mechanically treated (scraped) with suitable tools prior to
welding.
Should the joining surfaces need to be cleaned, non-fat cleaners
should be used.
9.2 Tacking
Tacking serves to fix the joining parts together in their intended
position to avoid displacement of the joining parts during welding.
Tacking is often carried out by melting the joining surfaces with a
special tacking nozzle or an equivalent nozzle attachment.
9.3 Hot-gas welding with torch separate from filler rod (WF)
In hot-gas welding with torch separate from filler rod, the joining
pressure is applied by hand via the welding filler. The welding
filler should be stretched, compressed or twisted as little as
possible in this process to minimize the occurrence of residual
stress in the weld.
At the beginning of a welding pass, it is recommended to slightly
bevel the tip of the welding filler.
The nozzle aperture should be directed into the welding zone at
an angle of approx. 45° to the base material. The base material
and the welding filler are plasticized with triangular fanning
motion in the direction of welding. The bevelled welding filler is
then pressed onto the desired point and the fanning motion
continued in the welding direction.
The joining pressure is applied by hand on the welding filler such
that it then forms a welding string.
During welding, a bow wave of plasticized material spreading in
front of the welding filler must be observed, as well as a welding
seam in the form of a uniform double bead on both sides of the
weld string-bead.
The welding parameters – joining pressure, temperature and the
heat penetration time resulting from the welding speed and the
material thickness – are to be balanced against each other
(welding parameters – see Supplement 1).
When commencing on a welding string already made or in the
case of round welds, proceed according to the representation in
Fig. 6. At the end of welding, the welding rod should not be
twisted off or torn off, but, for example, removed with a knife or
cutting pliers. After each welding pass the weld should be
reworked without scoring using a suitable scraper.
Commencing at the beginning
of a weld
Commencing within the weld
Figure 6. Welding rod positioning.
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Page 6 to DVS 2207-3

9.4 Hot-gas string-bead welding (WZ) 9.6 Thermal reworking

Residual stress within the weld can be reduced by tempering.
In hot-gas string-bead welding, the welding filler is pressed via The temperature conditions depend on the material and
the nozzle shoe at the end of the draw nozzle into the joining

R&D INTAKE MANIFOLDS

zone. At the start and finish of welds, the same procedure is to be
followed as in WF welding, Fig. 2.
The base material is preheated at the beginning of the actual
welding process with the stream of air from main nozzle aperture
in a fanning motion. The welding filler is then fed into the nozzle
and is also preheated. As soon as the surfaces of the joining
parts are plasticized, the filler is pressed into the prepared
welding joint with the tacking tip and the welding machine is
passed along the welding joint under uniform application of
joining pressure.
component. The specifications from the semi-finished products
manufacturer are to be observed.
9.7 Welding record sheet
The welding record sheet also documents the welding conditions
and the welding parameters. It forms the basis for the
assessment of the weld quality by the welding inspector (cf. DVS
2213 and the sample record sheet in Appendix 2).
10 Testing the welded joints

To avoid stretching of the welding filler through friction in the
nozzle, it may be necessary to feed the welding filler by hand.
The drawing motion along the welding joint takes place while
observing the emerging bow wave, the welding seam (double
bead) and the surface of the welding filler introduced. Scoring of
the base material arising from improper handling of the draw
nozzle (tacking tip) should be avoided.
After each welding pass, the weld should be reworked without
scoring using a suitable scraper, as with hot-gas welding with
torch separate from filler rod.
9.5 Mechanical reworking of the weld
It is normally not necessary to rework the weld. If the weld is
mechanically reworked, care should be taken to avoid scoring.
Reworking may only take place once the weld has cooled
sufficiently.
Destructive and non-destructive tests are distinguished. They are
shown in Table 3 “Possible test procedures”
Visual inspection takes place according to DVS 2202-1 and
particularly concerns the weld shape, score-free surfaces and
edges, optimal weld filling, continuous welding of the root and
displacement of the joining parts.
Defects inside the welds can be determined non-destructively
with ultrasound and x-ray testing (see DVS 2206). These
techniques alone cannot however provide an adequate indication
of the quality of the welded joint. The possibilities of applying
these test methods is also limited in regard to the weld geometry
and thickness.
The nature and scope of the tests to be undertaken in the
individual case are to be defined.
General material specific tests can be found in DVS 2201-1 and
DVS 2206.

Table 3. Possible testing methods for hot-gas welds.

Non-destructive testing
Visual inspection of the intact weld Visual inspection according to DVS 2202-1 and 2206
(external findings) The evaluation group is to be defined on a case-by-case basis
Seal test with vacuum Using a vacuum bell jar and foaming liquid; the test conditions are to be defined on a
case-by-case basis. Usual testing pressure -0.4 to -0.5 bar.
Seal test with high voltage The type of test equipment (with or without counter pole) and test voltage are to be
defined on a case-by-case basis. Testing methods according to DVS 2206, para.
3.3.1.4
Radiation transmission testing Applicability: Evidence with the number, position, shape and size of pores, shrink
holes and similar defects possible. Testing method according to DVS 2206, Section
3.5
Ultrasound testing Applicable with PE-HD, restricted with PP (evidence of hollow sites, not of quality)
Testing method according to DVS 2206, Section 3.4
Pressure testing Typical application for pipelines; Testing conditions according to the German
Pressure Tank Ordinance / Pressure Equipment Directive. Test performed according
to DVS 2219-1 Supplement 2 and DIN 4279
Evidence: Sealing quality, experimental evidence for operational safety
Destructive testing
Visual inspection of the weld cross-section Form of the weld cross-section (weld geometry), inner findings according to DVS
2202-1 Tab. 4 and 5. Fracture surface of the weld destroyed by tensile testing or
technological bending trials.
Tensile testing Execution according to DVS 2203-2. Rapid tension-weld factor; DVS 2203-4 tensile
creep weld factor; Minimum requirements according to DVS 2203-1
Testing not applicable for fillet and bevel welds.
Technological bending test Minimum requirements (bending angle/distance) according to DVS 2203-1
Testing not applicable for fillet and bevel welds.

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11 Safety instructions DVS 2205 Calculation of thermoplastic tanks and

apparatus
Some materials develop hazardous decomposition products and Part 3 Welded joints

R&D INTAKE MANIFOLDS

poisonous vapours if overheated (for example PVC, PVDF and
E-CTFE), others even when welded (for example FEP, MFA,
PFA, PTFE). In accordance with Article 20 of the German
Hazardous Substances Ordinance (GefStoffV) or according
national regulations, the company owner must produce operating
instructions based on the manufacturer’s safety datasheets,
which show all potential hazards and protective measures
required. Other specific protective measures are to be defined on
a case-by-case basis.
The applicable safety regulations pertaining to welding in EX
protected areas are to be observed and the necessary measures
are to be agreed with the safety office responsible; see the
German Workplace Safety Ordinance (BetrSichV) or according
national regulations in this regard.
12 Other applicable standards and technical codes
DIN 1910-3 Welding of plastics, processes
DIN 4279 Testing of pressure pipelines for water by
internal pressure – Low density PE-LD
polyethylene pressure pipelines, high
density PE-HD (PE 80 and PE 100)
polyethylene pressure pipelines, Cross-
linked PE-X polyethylene pressure
pipelines, unplasticized polyvinyl chloride
PVC-U pressure pipelines.
DIN 16960-1 Welding of thermoplastics – principles
DIN 32502 Imperfections in plastic welded joints;
classification, terminology, Explanations
DIN EN 10204 Metallic products – Types of inspection
documents
DIN EN 12943 Filler materials for thermoplastics
DIN EN 22553 Welded, brazed and soldered joints –
Symbolic representation on drawings
DIN EN ISO 1043-1 Plastics – symbols and abbreviated terms
DVS 2201-2 Testing of semi-finished products of
thermoplastics, weldability, test methods –
requirements
DVS 2202-1 Imperfections in thermoplastic welding
joints;
Features, descriptions, evaluation
DVS 2203 Testing of welded joints of thermoplastics
Part 1 Test methods – requirements
Part 2 Tensile test
Part 4 Tensile creep test
Part 5 Technological bending test
Part 4 Flanged joints
Part 5 Rectangular tanks
DVS 2206 Testing of components and constructions
made of thermoplastic materials
DVS 2207-1 Welding of thermoplastics – electro fusion
welding of pipes made of PE-X with
pipeline components and sheets made of
PE-HD
DVS 2207-3 Hot-gas welding of thermoplastics – hot-
Supplement 1 gas welding with torch separate from filler
and string-bead welding of pipes, pipeline
components and sheets – welding
parameters
DVS 2207-3 Hot-gas welding of thermoplastics – hot-
Supplement 2 gas welding with torch separate from filler
and string-bead welding of pipes, pipeline
components and sheets – welding
equipment requirements
DVS 2207-3 Hot-gas welding of thermoplastics – hotgas
Supplement 3 welding with torch separate from filler and
(in preparation) string-bead welding of pipes, pipeline
components and sheets – welding of fluor
plastics
DVS 2207-4 Welding of thermoplastics; extrusion
welding of pipes, pipe components and
sheets – Welding processes, requirements
DVS 2207-5 Welding of thermoplastics; Welding of PE-
pipe jacktets – pipes and pipe components
DVS 2207-11 Welding of thermoplastics – heated tool
welding of pipes, pipeline components and
sheets made of PP
DVS 2207-15 Welding of thermoplastics – heated tool
welding of pipes, pipeline components and
sheets made of PVDF
DVS 2210-1 Industrial pipelines made of thermoplastics
– planning and execution – above-ground
pipe systems
DVS 2211 Filler Materials for thermoplastics – scope,
designation, requirements and tests
DVS 2212-1 Examination of plastic welders: Examina-
tion groups I and II
DVS 2213 Plastic welding specialist – Examination
DVS 2225 Joining of lining membranes made of
polymer materials in geotechnical and
hydraulic engineering
DIN standards may be obtained from Beuth Verlag, Berlin, DVS
technical codes from Verlag für Schweißen und verwandte
Verfahren DVS-Verlag GmbH, Düsseldorf.

349
Page 8 to DVS 2207-3

Appendix 1: Brief instructions for welding 4. Commissioning welding equipment and setting parameters
(Section 7)
1. Compile welding equipment (Section 8.1) – Check supply lines (electricity, air) for any possible interrup-

R&D INTAKE MANIFOLDS

– Valid welding certificate in accordance with DVS 2212-1 tion of the welding process.
– Hot-gas welding equipment with operating instructions – Connect and switch on the welding equipment according to
the operating instructions
– Welding nozzles suitable for the welding job and the wel-
ding filler – Select and fit hot-gas nozzle; set hot-gas flow rate and tem-
perature and check (Supplement 1)
– Flowmeter for welding gas
– Temperature meter with probe to measure the hot-gas and 5. Prepare the weld and joining surfaces (Section 5.8)
the semi-finished product temperature.
– Check weld geometry and shape, define and produce as re-
– Suitable measuring equipment to check displacement, dia- quired
meter, thickness
– Mechanically remove the oxide layer from the joining sur-
– Equipment storage facilities faces with abrasion immediately prior to welding
– Scraper, retractable blade
– Personal protective equipment 6. Tacking the joining surfaces (Section 9.2)
– Dust protection for welding filler – Partial or continuous tacking with tack nozzle
– Cleaning agent
7. Welding (Sections 9.3, 9.4)
– Supplement 1 Welding parameters
– Monitor the welding speed and check uniformity
– Appendix 2 Welding record sheet
– Continuously check the handling of the welding filler and
– Special welding instructions, as required
the draw nozzle and perform necessary corrections

2. Check working conditions and plan measures – Bevel the weld end before commencing afresh
(Section 8.2) – Scrape the weld seam of each weld zone before applying
– Accessibility further weld
– Adequate illumination – Protect the welding filler from soiling
– Protective tent
8. Reworking the welds (Section 9.7)
– Heating
– Allow the welded parts to cool down sufficiently before un-
– Measurement of the semi-finished product temperature and clamping and loading
introduce measures, as required
– Mechanically process weld scoring and the welding seam
on the weld flanks
3. Check welding suitability (Section 6.1)
– Check the manufacturer’s specifications on the semi-fin- 9. Complete the welding record sheet (Section 9.6)
ished products and welding filler for compatibility
– Complete the welding record sheet (Appendix 2) and carry
– Check the identity, condition and cleanliness of the joining
out visual inspection according to DVS 2202- 1
parts and clean as required
– Check the weldability of the joining parts with contract weld-
ing according to DVS 2201- 2 or test welding

350
 Appendix 2: Welding record sheet

Hot-gas welding of sheets and pipes Company logo

Welding record sheet
Project name: Project no.: Weather Protective
measures
Drawing no.: Base material (manufacturer, type, batch, date) form: 1 = sunny 1 = none
Welder: Welding filler (manufacturer, type, batch, date): 2 = dry 2 = screen
Welding certificate no.: / valid until, issued by: Welding equipment (make, type): 3 = precipi- 3 = tent
3 = tation
Welding inspector (2): Nozzle(s): 4 = wind 4 = heating

Date Construction Weld Joining Weld Process Air flow (1) Hot-gas Ambient Semi-finished Weather Protective Visual
detail no. part shape WF, WZ l/min temperature temperature product temp. (code no.) measures assessment
thickness (symbol) °C °C °C (code no.)
mm

(1) Measured in the middle of the nozzle exit aperture, 5 mm inside

the nozzle Remarks, e.g. adverse conditions
(2) e.g. plastic welding specialist as defined in DVS 2213
R&D INTAKE MANIFOLDS

Date / welder signature Date / welding inspector signature

Page 9 to DVS 2207-3

351
 Draft May 2009

Welding of thermoplastics
DVS – DEUTSCHER VERBAND High-speed hot gas welding and hot gas welding
FÜR SCHWEISSEN UND with the torch separate from the filler rod of pipes, Technical Code
VERWANDTE VERFAHREN E.V. piping parts and panels DVS 2207- 3
Welding parameters Supplement 1
R&D INTAKE MANIFOLDS Comments until August 31, 2009

Planned as replacement for April 2005 edition

This draft is presented to the public for examination and comments. Proposals for additions or modifications should be sent to DVS
e. V., P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, before the date mentioned above.

This supplement to the DVS 2207-3 technical code includes guide values for the parameters for high-speed hot gas welding and for hot
gas welding with the torch separate from the filler rod. They apply to manual welding with the devices described in the DVS 2207-3
technical code, Supplement 2 and with the materials listed in the table. Guide values for the parameters for thermoplastic fluoroplastics
are included in the DVS 2207-3 technical code, Supplement 3.
In addition, before the application of the parameters, attention must also be paid to the information from the manufacturers of the semi-
finished products.
By coordinating the hot air temperature, air volume and welding speed parameters, it must be guaranteed that the joining parts are
plasticised at the joint down to a depth of min. 0.3 mm.
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

Materials Abbreviations Hot gas Hot gas volume Welding speed 3) Welding force (N)
Welding 
process

temperature 1) flow 2) with wire 

°C l/min mm/min 3 mm 4 mm

High-density
torch separate from the filler rod (WF)

PE- HD 4) 300 … 320 70 … 90

polyethylene
8 - 10
Polypropylene,
Hot gas welding with the

PP-H; PP-B; PP-R 305 … 315 60 … 85

Types 1, 2 and 3
20 … 25
Unplasticised
PVC-U 330 … 350 110 … 170 8 … 10
polyvinyl chloride
Chlorinated 40 … 50
PVC-C 340 … 360 55 … 85
polyvinyl chloride

15 … 20
Polyvinylidene
PVDF 350 … 370 45 … 50 25 … 30
fluoride

High-density
PE- HD 300 … 340
High-speed hot gas welding

polyethylene
Polypropylene,
PP-H; PP-B; PP-R 300 … 340 250 … 350 15 … 20 25 … 35
Types 1, 2 and 3
Unplasticised
(WZ)

PVC-U 350 … 370 45 … 55

polyvinyl chloride
Chlorinated
PVC-C 370 … 390 180 … 220
polyvinyl chloride
20 … 25 30 … 35
Polyvinylidene
PVDF 365 … 385 200 … 250
fluoride

1) Measured 5 mm in the nozzle, in the centre of the nozzle opening.

2) Drawn-in cold air volume at the ambient pressure.
3) Depending on the welding filler material diameter and the welding groove geometry.
4) PE 63, PE 80 and PE 100.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group “Joining of Plastics”

Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49 (0) 211/1591- 0, Telefax: + 49 (0) 211/1591- 150

352
 Erstellungsdatum: 15.06.2007
Letzte Änderung: 09.07.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3-Bb2.fm

September 2007

Welding of thermoplastics
DVS – DEUTSCHER VERBAND Hot-gas string-bead welding and hot-gas welding
FÜR SCHWEISSEN UND with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Requirements for DVS 2207-3

R&D INTAKE MANIFOLDS

welding equipment and accessories Supplement 2

Translation of the German version from April 2005

Contents: – the nozzles used are also easy to remove and fit in the heated
state,
1 Applicability
– a constant welding temperature is achieved after a maximum
2 Requirements
of 15 minutes,
2.2 Safety requirements
2.3 Labeling and documentation – the operating controls are protected against inadvertent
2.4 Hot-gas supply displacement.
2.5 Nozzles
2.6 Flowmeters 2.2 Safety requirements
3 Other applicable standards and technical codes
The equipment used in a proper manner must afford the user
protection against injuries of any nature. The applicable statutory
regulations governing the use of equipment must, in particular,
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

1 Applicability
This supplement to technical code DVS 2207- 3 describes, in
general terms, qualitative and safety-relevant requirements for
welding equipment and the necessary accessories for hot-gas
string-bead and hot-gas welding with torch separate from filler
rod (WZ, WF) of thermoplastics.
It applies to the types of equipment described in technical code
2207-3, with and without built-in hot-gas supply, as well as
controlled or regulated, and serves to ensure that the required
weld quality is achieved provided the equipment is operated and
handled correctly.
Special devices for special applications are not covered within
the scope of this supplement.
2 Requirements
2.1 General requirements
The equipment must ensure that
– safe functionality is ensured within the intended temperature
application range (- 5 to + 60 °C),
– storage within a temperature range of - 5 to + 60°C causes no
damage,
– no faults or damage arise as a result of the mechanical strain
arising during proper transportation and operation,
– there is adequate corrosion protection against moisture
entering from the outside,
be observed. (Also see Section 3)
Additionally applicable:
– Parts in close proximity to hands must not exceed + 40°C
under operating condition even after prolonged usage.
– Equipment surfaces presenting a burn hazard are to be kept
as small as possible, or isolated and labelled as required.
– Over-temperature protection must be fitted to avoid overheat-
ing or destruction of the equipment or individual elements (for
example due to a shortage of air).
– Sharp edges on equipment and accessories are to be avoided.
2.3 Labelling and documentation
All equipment must display at all times:
– specifications of manufacturer and model,
– specifications on power supply, power consumption and fre-
quency,
– identification number,
– CE mark and protection class.
All equipment must include operating and maintenance instruc-
tions, which contain at least:
– functional description and operating instructions,
– specifications on areas of application,
– maintenance schedule specifying service intervals,

– the equipment elements are ergonomically designed according – service addresses.

to their intended use and are as light as possible and may be
operated easily and safely,
– the handle has no preferred direction in relation to the supply
lines and that the nozzle can be fixed in any position,
– the functional elements are easily accessible for proper
operation and for the necessary cleaning and maintenance
and that expendable parts are easy to replace,
– feed hoses and cables can be extended by the welder with the
minimum of effort and do not kink or twist in proper operation,
– they can be stored safely when welding work is finished or
during interruptions,
A compilation of potential functional faults is recommended,
including possible causes and information on rectification.
2.4 Hot-gas supply
Irrespective of the equipment construction, the welding gas
supply must ensure that
– the welding gas is free of dust, water and oil,
– the gas volume remains constant during welding and an air
flow matched to the welding job according to DVS 2207-3
Supplement 1 is provided even if several welding tools are in
continuous operation,

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group ″Joining of Plastics″

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

353
Page 2 to DVS 2207-3 Supplement 2
– the required air flow rate is adjustable for each welding tool
and is displayed with an accuracy of ± 5 l/min,
– the temperature fluctuations at the nozzle do not exceed ± 5 K
R&D INTAKE MANIFOLDS
independent of voltage or air flow fluctuations, nozzle
geometry and differences in ambient temperatures,
– setting of the welding temperature is easy and sensitive and
cannot be inadvertently displaced,
– the output gas volumes fluctuate in a maximum range of ± 5%
from the set value, independent of process-related counter-
pressure fluctuations (for example unfavourable nozzle
position).
For welding torches with integrated air supply it must be ensured
that
– the air suction openings are fitted such that they allow
sufficient entry of air at all times for proper use of the
equipment (for example no covering with hands),
– the filter element is easy to change.
In the case of an external welding gas supply, the temperature of
the gas from the central supply must not exceed 50°C
2.5 Nozzles
For nozzles in hot-gas string-bead welding:
– The nozzles must match the cross-section of the welding filler
to be used and must also allow the smooth passage of welding
filler taking into account its volume expansion.
– The leading surface of the nozzle shoe must be polished.
– The nozzle material must be resistant to oxidation and
corrosion.
– The nozzle shoe must be formed such that its edges do not
score the base material.
The aforementioned statements apply in principle as well to
pressure rollers for welding soft materials (e.g. soft PVC).
2.6 Flowmeters
Flowmeters to measure and regulate the flow of hot gas must not
exceed a maximum deviation of 3.0% of the maximum scale
value. They should normally be designed for 100 l/min under
normal conditions at 20°C and average working pressure of the
equipment connected. Suspended body flowmeters or orifice
flowmeters calibrated with pre-pressure display in standard litres
have proven effective.
354
3 Other applicable standards and technical codes
EN 55014-1 EMC testing: emission
EN 55014-2 EMC testing: immission
DIN EN Electrical equipment of industrial machines
60204- 1
EN 61000-3-2 Electromagnetic compatibility (EMC) Part 3-2:
Limit values – limit values for harmonic current
emissions (equipment input currents 16 A per
phase)
EN 61000-3-3 Electromagnetic compatibility (EMC) Part 3-3:
Limits: Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage
supply systems, for equipment with rated cur-
rent 16 A per phase and not subject to condi-
tional connection.
EN 60335-1 Safety for household and similar electrical
appliances – Part 1: General requirements
EN 60335-2.45 Safety for household and similar electrical
appliances – Part 2-45: Special requirements
VDE 0875 Radio interference suppression of electrical
devices and systems for rated frequencies of 0
to 10 kHz
DVS 0801 Flow measurement of technical gases for weld-
ing, cutting and related procedures
DVS 2207-3 Hot-gas welding of thermoplastics – hot-gas
string-bead and hot-gas welding with torch
separate from filler rod of pipes, pipeline com-
ponents and sheets – methods, requirements
DVS 2207-3 Hot-gas welding of thermoplastics – Hot-gas
Supl. 1 welding with torch separate from filler and
string-bead welding of pipes, pipeline compo-
nents and sheets – welding parameters
 File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-4\englisch\Jan_08\e2207-4.fm
Erstellt am: 18.01.2005
Zuletzt geändert am: 29.01.2008

March 2008

DVS – DEUTSCHER VERBAND Welding of thermoplastics Extrusion

FÜR SCHWEISSEN UND welding of pipes, piping parts and panels Technical Code
VERWANDTE VERFAHREN E.V. Processes and requirements DVS 2207-4

R&D INTAKE MANIFOLDS Translation of the German version from april 2005

Contents: The technical code can be correspondingly applied to other

materials and material modifications (e.g. electrically conductive).
1 Scope of application It is necessary to pay attention to supplementary instructions
2 Materials from the manufacturers of the semi-finished products.
3 General process description
3.1 Continuous welding process
3.2 Discontinuous welding process 3 General process description
4 Machine variants
4.1 Machine Variant I Extrusion welding is a manual or semi-automatic welding proc-
4.2 Machine Variant II ess. It is performed with a welding filler which consists of wire or
4.3 Machine Variant III granules and is melted and plastified in a plastifying system (ex-
5 Structural design, weld shapes and weld structure truder). A welding shoe shaped according to the weld geometry
6 Requirements serves to press the welding filler into the base material welding
6.1 Requirements on the welding machines and devices groove which is plastified with hot air as a rule. Other heat sourc-
6.2 Requirements on the welding shoes
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

es or carriers may be, for example, a light ray or inert gases. The
6.3 Requirements on the preheating material output capacity of the machines or devices determines
6.4 Requirements on the materials and their weldability the maximum weld dimensions and influences the welding
6.5 Requirements on the welders speed. The necessary joining pressure is generated by the
6.6 Requirements on the quality of the welded joints emerging material and the counterforce of the welder.
7 Start-up of the welding machines and setting of the welding
parameters A distinction is made between the following processes:
8 Welding preparation – continuous welding process
8.1 Equipment
– discontinuous welding process
8.2 Protective measures against environmental influences
9 Welding
9.1 Preparation of the joining faces 3.1 Continuous welding process
9.2 Tacking The plastified welding filler emerging from the manually or
9.3 Execution of a weld mechanically guided device or machine is continuously pressed
9.4 Finish machining of the welds into the also plastified welding groove by a welding shoe, Figs. 1,
9.5 Thermal after-treatment of the welds 3 and 4.
9.6 Welding record sheet
10 Testing of the welded joints
11 Safety instructions
12 Standards and technical codes which are also applicable
Appendix 1: Brief instructions for the welding
Appendix 2: Welding record sheet for the extrusion welding

1 Scope of application

This technical code applies to the hot gas extrusion welding

(hereinafter called extrusion welding) of pipes and panels in tank,
apparatus and pipeline construction as well as during the
manufacture of self-supporting collecting pans and of seals on
concrete structures with thermoplastics. It describes the different
processes, indicates the process limits and stipulates
requirements for the quality assurance.
Special instructions for the extrusion welding of sealing sheets in
earthwork construction and water engineering are included in the
DVS 2225-1 and DVS 2225-4 technical codes. Instructions for
the extrusion welding of casing pipes can be found in the
DVS 2207-5 technical code.

2 Materials

This technical code applies to the materials specified in the

DVS 2207-4 technical code, Supplement 1. Figure 1. Diagram for continuous welding with Machine Variant I.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group “Joining of Plastics”

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

355
Page 2 to DVS 2207-4
In the case of manual welding, the feed speed results from the
volume of the emerging material flow and from the weld cross-
section to be filled. In the case of welding with a feed system, the
welding speed must be adjusted to the material output.
welding head. R&D INTAKE MANIFOLDS
The welding zone is preheated by a hot gas fan attached to the
3.2 Discontinuous welding process
For the welding, the plastified welding filler is extracted from the
extruder section by section with a corresponding quiver, is
inserted into welding groove plastified with a hot gas device and
is pressed in, shaped and smoothed with a press-on tool (Fig. 2).
Figure 2. Diagram for discontinuous welding with Machine Variant II.
356
This process is predominantly used where confined space-
related conditions or certain structural details exclude continuous
welding.
4 Machine variants
The machines or devices consist of:
– the plastifying system (extruder) for the plastification of the
input welding filler
– the preheating system for the heating of the joining faces (as a
rule, hot air)
– the welding head in order to accommodate the welding shoe
and the preheating system
– the welding shoe in order to input the extrudate into the
welding groove and to shape the surface (alternative to the
quiver and the press-on tool in the case of discontinuous
welding)
4.1 Machine Variant I
Machine or device type in which all the device components form
one unit. As a rule, the welding filler is supplied to the device as
round wire or, in the case of larger devices, also as granules, Fig. 1.
4.2 Machine Variant II
The extruder and the welding head are structurally separate in
the case of this machine type. For continuous welding, both
machine parts are connected with each other by a heated hose
for the welding filler, Fig. 3. For discontinuous welding, the
extrudate is extracted directly from the extruder using
replaceable material nozzles, Fig. 2.
The machines of this type have a high output capacity but are
primarily used in stationary operation due to their size. The
welding filler is usually supplied to the device in granule form.
4.3 Machine Variant III
The machines or devices consist of the welding wire intake
station, the plastifying unit and the preheating system. The
welding filler in wire form is transported into the heating chamber
by the wire feed unit which inputs the plastified welding filler into
the joining zone via the welding shoe, Fig. 4. As a rule, the
devices are smaller and easier to handle than Machine Variants I
and II but also have a lower output capacity.
Figure 3.
Diagram for continuous welding
with Machine Variant II.
 Page 3 to DVS 2207-4

For materials others than those listed in Appendix 1, it may be

necessary to choose different weld shapes and weld preparation
angles.

R&D INTAKE MANIFOLDS

Desination Sheme Symbol
V- seam
V-seam

V
Double-V-seam
Double-V-seam
(X-seam)
(X-seam)
X
Double-HV-
Double-HV-seam
seam
(K-butt) (K-
butt)
K

Fillet
Fillet
Figure 4. Diagram for continuous welding with Machine Variant III.

5 Structural design, weld shapes and weld structure

The DVS 2205 ff. technical codes apply to the structure of the
components and the DVS 2205-3 technical code to the design of
the welds (the supplements to the respective technical codes are Figure 5. Examples of weld shapes and weld symbols.
also applicable). In particular, attention must be paid to the
following:
Depth of seams s (mm)

– Crossing welds must be in a staggered arrangement. V- and double V-seams

– The distance between the welds should be about three times HV-seams
the width of the top layer but min. 50 mm.
– In the case of butt joints, it is necessary to match the work-
piece thicknesses of connecting ends with different thick-
nesses (DVS 2205).
– A weld shape which guarantees that the cross-section of the
thinner joining part in each case can be connected completely
(e.g. T-joint with a single-bevel butt weld) should be chosen in Angle of seam opering (’’)
the case of accessibility from one side only.
a) Continuous welding
DIN EN 22553 applies to the designation and graphical and
symbolic representation of the welds.
Depth of seams s (mm)

The most important weld shapes are single-V, double-V, single-

bevel and double-bevel butt welds as well as fillet welds.
HV-seam V- and double V-seams
Examples of the execution of welds as well as their symbolic
representation on fabrication drawings are shown on Fig. 5.
As a rule, the welds are manufactured in a single layer or, in
special cases, in multiple layers.
In order to reduce the weld volume and because of the more
uniform distribution of the residual welding stresses, the welds
should, if at all possible, be executed on both sides or with a Angle of seam (’’)
backing layer (double-V butt weld, fillet weld and double-bevel
butt weld). b) Descontinuous welding
The material input into the welding grooves should be minimised
because of the shrinkage stresses arising during the cooling of Figure 6. Recommended weld preparation angles for PE-HD and PP in
the case of single-V and single-bevel butt welds depending on
the welds. It is therefore recommendable to change the weld
the weld depth and the welding process (for other materials, it
preparation angle according to the joining part thickness, Fig. 6. may be necessary to choose different weld preparation angles).
The residual root opening should be max. 1 mm and full-
penetration welding must be ensured.
6 Requirements
The root gap should not exceed 2 mm in the continuous welding
process and 4 mm in the discontinuous welding process. If the 6.1 Requirements on the welding machines and devices
root gap width cannot be complied with for structural or design-
related reasons, appropriate measures must be taken (e.g. using The welding machines and the welding devices must be in a
a backing strip). functioning condition. Their condition and good working order

357
Page 4 to DVS 2207-4
must be checked regularly (e.g. by means of monitoring by the
manufacturers).
The output quantity and the preheating capacity must be
R&D INTAKE MANIFOLDS
adjusted to the welding job.
Special requirements on the welding machines and the welding
devices are described in Supplement 2 to this technical code.
6.2 Requirements on the welding shoes
The joining pressure necessary for the welding is applied to the
joining faces with the welding shoe via the welding filler. At the
same time, the welding shoe shapes and smooths the weld
surface.
Therefore, the welding shoes must correspond to the welding job,
must be structurally adjusted to the respective weld shapes and
thicknesses (Fig. 7), must have smooth, anti-adhesive surfaces
and must be sufficiently temperature-resistant.
a) Welding shoe for
single-V welds
b) Welding shoe for
fillet welds
Figure 7. Representations of welding shoe designs.
As a rule, they are made of polytetrafluoroethylene (PTFE). This
material possesses the specified properties and is easy to
machine.
The lengths of the press-on zone and the smoothing surface
should not be less than the minimum lengths specified in Table 1.
This ensures that the joining pressure acts during a minimum
time and that the necessary bond can thus be produced
throughout the joining area (especially the weld root and the weld
sidewalls).
358
The weld overlap ∆b should be more than or equal to 0.2 times
the joining part thickness but it should be min. 3 mm.
The weld reinforcement ∆s should be 0.1 - 0.2 times the joining
part thickness.
The "nose" located on the front part prevents the material from
flowing ahead, is a prerequisite for the generation of the
necessary joining pressure and supports the forward movement
of the welding device. It must correspond to the welding groove
shape but must not touch the welding groove faces during the
welding.
The gap between the nose and the weld sidewalls should be
1 - 3 mm depending on the weld thickness.
The undercut on the contact surfaces prevents molten base
material from being pushed away.
When press-on tools are used for discontinuous welding, the
above stipulations are applicable correspondingly.
Table 1. Guide values for welding shoe dimensions.
Seam depth s for V-seams s Pressing length LA
(mm) (mm)
to 15 35
> 15 to 20 45
> 20 to 30 55
6.3 Requirements on the preheating
The preheating must guarantee that the joining faces and the
areas of the weld overlap, Fig. 8, are sufficiently plastified even
when the welding groove geometry changes. The welding shoes
and the preheating (nozzle geometry, air volume and hot gas
temperature) must be coordinated.
6.4 Requirements on the materials and their weldability
Semi-finished products and welding fillers (wire and granules)
must be suitable for extrusion welding. One prerequisite for
welded joints which should meet the requirements according to
DVS 2203 is the use of a welding filler of the same type as the
base material but at least of a similar type.
For the semi-crystalline materials (such as PE, PP and PVDF),
reference is made to the melt index as a characteristic parameter
for the weldability. If the melt index (MFR) values of the welding
partners are within the permissible melt index ranges in
DVS 2207-1, -11 and -15, weldability may be assumed in
general. If two semi-finished products in different MFR groups
from these ranges are to be welded with each other, it is
necessary to choose a welding filler whose MFR value is
between that of the combination of semi-finished products. For
PE-HD, PP and PVDF, attention must be paid to the instructions
in the scope of application of the DVS 2207-1, 2207-11 and
2207-15 technical codes. If the melt index is outside the
authorised ranges in the specified technical codes, the welding
evidence according to DVS 2203-4 must be provided in the
tensile creep test.
The following applies to amorphous materials such as PVC:
"Only semi-finished products of the same moulding material type
are weldable."

The semi-finished products and the welding fillers must be
marked correspondingly and unmistakably (in the case of
welding fillers, on the packaging).
R&D INTAKE MANIFOLDS
Only semi-finished products with stipulated quality requirements
should be welded (e.g. works certificate according to DIN EN
10204).
The welding fillers must meet the requirements according to the
DVS 2211 technical code and DIN EN 12943.
The base and filler materials must be available in a flawless
processing condition and must be dry and clean.
If there are any doubts that the semi-finished products and/or the
welding filler are similar (e.g. due to a lack of labelling) or if any
material changes are to be feared due to:
– improper storage
– low joining part temperatures
- soiling
– ageing
– operating influences (media or temperatures)
it is necessary to establish the weldability by means of tests on
trial welds. Agreement must be reached with regard to the type
and scope of the tests. Instructions about this are given in the
DVS 2203-1 and 2201-2 technical codes.
6.5 Requirements on the welders
Hot gas extrusion welding is a welding process for which not only
comprehensive knowledge with regard to the materials to be
welded and to the handling of the machines and devices but also
high skills in the execution are prerequisites.
The welder must have passed a qualification test according to
the DVS 2212-1 technical code, Qualification Test Group II, and
must possess a valid test certificate.
6.6 Requirements on the quality of the welded joints
If the welds are executed properly according to this technical
code, those minimum requirements on the quality of the welds
which are specified in the DVS 2203-1 technical code (welding
factors and bending angles) are sure to be met. With regard to
the application in question, to statutory stipulations if needed
(Water Management Act, Pressure Device Directive etc.) and to
the necessary dimensioning, the customer and the manufacturer
should agree on the corresponding requirements on the
component and on the welded joints and should stipulate these.
Instructions and criteria for stipulating the quality are described in
the DVS 2202-1 technical code. The inclusion of the weld quality
in the component calculation is described in the DVS 2205-1 to
-5 technical codes.
If necessary, the evidence of the demanded quality may be
provided within the framework of establishing its suitability on trial
welds with reference to DVS 2212-1. This applies especially to
materials for which no requirements have yet been stipulated in
the specified technical codes (e.g. PVC-C).
7 Start-up of the welding machines and setting of the
welding parameters
The start-up is carried out according to the operating instructions
from the machine manufacturer.
Extrudate residues in the extruder, at the outlet opening as well
as, if applicable, in the transport hose must be melted completely
before the extrusion drive is switched on.
In order to avoid the use of thermally predamaged welding filler,
the reheated melt should be extruded out completely before the
beginning of the welding. This also applies to longer interruptions
in the work. The maximum dwell times are dependent on the
material in question (in the case of PE-HD and PP, approx.
5 min). In the case of thermally sensitive materials such as PVC
and PVDF, it is to be recommended to keep the extruder running
during the interruption in the welding.
Page 5 to DVS 2207-4
If the material is changed, it must be ensured, by means of
cleaning or extruding-out, that all the material in the welding
extruder is replaced. If necessary, the nozzles must be changed.
In the case of Machine Variant II, the hose must always be
changed as well. It is recommended not to use the same extruder
for different materials in practice.
The welding filler must be dry. If necessary, it must be dried
before use (e.g. several hours in an exhaust air oven at
temperatures of approx. 60 - 80°C). Attention must be paid to the
information from the welding filler manufacturer.
While the machine is running, the required material temperature
is checked directly at the material outlet in the middle of the
strand using the prick sensor of a quick-display temperature
gauge.
The control measurement of the hot air temperature is taken in
the hot air nozzle between the nozzle outlet plane and a depth of
5 mm using a precision probe with a diameter of approx. 1 mm
(see the instructions in DVS 2207-4, Supplement 2).
The stipulated air volume must be checked in the case of devices
with an external air supply. It is necessary to ensure the flawless
function of devices with an internal air supply.
The material and hot gas temperatures must be checked
immediately before the beginning of the welding. Repeat checks
are recommendable in the case of a welding job lasting a longer
time or after interruptions in the work.
All the measurements must be taken with regularly checked
measuring instruments (according to DVS 2207-4, Supplement
2) and must be documented (Appendix 2).
8 Welding preparation
The welding grooves of the joining parts are prepared according
to Section 5.
It must be guaranteed that the welding head of the machine or
device has sufficient accessibility to the joining faces. Welding
out of position should be avoided or minimised because of the
required counterpressure to be applied by the welder. It must be
ensured that the welder is not hindered during the welding as a
result of the necessary readjustment of the connecting cables
and hoses as well as of the welding filler.
8.1 Equipment
The following equipment constitutes the minimum requirements
for the proper execution of the welded joints:
– hot gas extrusion welding device according to the welding job
and this technical code
– welding shoes according to the welding job
– flow meter for welding gas
–- temperature gauge according to DVS 2207-4, Supplement 2
– suitable measuring instruments for checking the misalignment,
the diameter and the thickness
– suitable storage space for the devices
– scraper and scraper blade
– personal protective equipment
– dust protection for the welding wire
– sufficient lighting
– protective measures against weathering influences (see
Section 8.2)
– special cleaning agent (not swelling, dissolving or containing
greasy) and non-fraying rags
– welding parameters according to DVS 2207-4, Supplement 1
and/or instructions from the manufacturers of the semi-finished
products
– welding record sheet according to Appendix 2
359
Page 6 to DVS 2207-4
8.2 Protective measures against environmental influences
The ambient conditions may exert a fundamental influence on the
welding operation and thus on the quality of the joint. Therefore,
R&D INTAKE MANIFOLDS
attention must be paid to the following:
– The welding area must be protected from unfavourable
weathering influences (such as moisture, formation of
condensation water, wind, draughts and temperatures below
+ 5°C).
– If it is ensured, by taking suitable measures (e.g. preheating,
tenting or heating), that a semi-finished product temperature
sufficient for the welding can be complied with, the welding
may be carried out at any outdoor temperature – provided that
the dexterity of the welder is not hindered. If necessary,
additional evidence must be provided by manufacturing and
testing trial welds in the existing conditions.
– In the case of non-uniformly tempered joining parts (e.g. due to
solar radiation on one side, in the case of different storage
conditions etc.), the temperatures must be equalised before
the welding.
9 Welding
9.1 Preparation of the joining faces
The joining faces must not be damaged, oxidised or soiled.
Therefore, they and the adjacent weld overlap areas must be
subjected to chip-producing machining immediately before the
welding.
Chip-producing tools such as scrapers, scraper blades, milling
cutters and saws are suitable. Grinding tools are only permissible
if it is possible to exclude the soiling caused by inputting
abrasives and the overheating of the surfaces.
Especially in the case of joining parts which have been exposed
to the influence of UV or media for a long time, the damaged
layer may be so deep that the residual wall thickness, including
the static requirements, must be checked after the machining-off.
If the joining faces must be cleaned, it is necessary to use special
cleaning agents which do not contain any grease.
9.2 Tacking
Tacking serves to fix the joining parts in their planned positions in
relation to each other in order to exclude any changes in the
positions of the joining parts during the welding. Tacking is
usually carried out by means of the partial or continuous high-
speed hot gas welding of a root layer with a welding filler wire.
9.3 Execution of a weld
Before the beginning of the welding operation, the welding shoe
must be heated up (e.g. using a baffle plate) since welding with a
cold welding shoe results in a rough and uneven weld surface.
This also applies to press-on tools in the case of discontinuous
welding.
The start of the weld is preheated and completely melted with hot
air. Immediately before the welding shoe is placed on the welding
groove, the welding filler which has already emerged is removed
from the welding shoe opening. After the filling of the groove, the
material pressure builds up due to the counterpressure generat-
ed by the welder and the forward movement of the welding shoe
begins.
In the case of manual welding, the welding speed is determined
by the material output of the extruder and the size of the weld
cross-section.
The preheating of the joining parts must be adjusted to the
welding speed in such a way that the base material is plastified
down to a depth of 0.5 - 1 mm.
The plastification zone must be wider than the weld width. Guide
value: weld width + 2 • (0.2 • joining part thickness s) (see Fig.
8).
The melting depth is checked directly in front of the welding shoe.
This may be carried out with a thin, blunt tool.
360
The welder must ensure that the molten base material at the weld
sidewalls is not pushed off by the welding shoe nose.
In the case of restarts and at the end of circumferential welds, it is
necessary to diagonally machine off the already executed ends
of the weld.
Figure 8. Example of a single-V butt weld with representation of the mel-
ting zones and the weld overlap.
In order to avoid the excessively rapid cooling of the top layer
and the resulting formation of shrinkage cavities, it is
recommended to cover the extrusion weld immediately after the
welding.
If multi-layer welds are necessary, the cooled weld sidewalls and
surfaces of the already welded layers must be subjected to chip-
producing machining.
Design-induced modifications to the weld geometry in the weld
path (e.g. in the case of segment bends and branches) demand
particularly careful guidance of the welding shoe. If necessary,
the welding shoe must be changed.
In the case of semi-automatic and fully automatic systems and
facilities for extrusion welding, the welding parameters (the
material output, the preheating and the welding speed) must be
coordinated and must be set correspondingly.
It is recommended to manufacture trial welds.
In the case of discontinuous welding, the welding filler is
extracted from the extruder with the quiver and is inserted into
the plastified welding groove section by section. The joining
pressure is applied with the press-on tool across all the cross-
sectional areas of the weld (central and edge areas) in several
operations and the weld surface is shaped at the same time.
9.4 Finish machining of the welds
Subject to corresponding welding shoe formation and machine
guidance during the welding, finish machining of the welds is not
necessary (in this respect, see also DVS 2202-1, Table 5).
It is imperative to remove the lateral flow which may be pressed
through under the contact surfaces of the welding shoe.
Reinforced weld beads and reinforced weld roots must be
machined off correspondingly without any notches.
The weld may only be machined off after sufficient cooling.
9.5 Thermal after-treatment of the welds
Residual welding stresses can be reduced by means of
tempering. The tempering conditions depend on the material and
the component. Attention must be paid to the information from
the manufacturers of the semi-finished products.
9.6 Welding record sheet
The completely filled-in welding record sheet documents the
welding conditions and parameters amongst other details. It is
the foundation for the evaluation of the weld quality by the
welding supervisor (compare DVS 2213, specimen record sheet
in Appendix 2).
 Page 7 to DVS 2207-4

10 Testing of the welded joints

A distinction is made between non-destructive and destructive

test procedures. They are listed in Table 2 "Possible test

R&D INTAKE MANIFOLDS

procedures" for the most frequent weld shapes.

Table 2. Usual test procedures for extrusion welds, applicability and requirements.

Non-destructive tests
Visual inspection of Visual inspection, according to DVS 2202-1 and 2206. The evaluation group must be stipulated in each
the undestroyed weld individual case.
(external findings)
Leak test with a partial Using suitable vacuum bell jars and a foaming liquid; the test conditions must be stipulated in each
vacuum individual case. Usual test pressure: -0.4 bar to -0.6 bar.

Leak test with electric The type of test device (with or without an antipole) and the test voltage must be stipulated in each
high voltage individual case. Test technique according to DVS 2206, Section 3.3.1.4.

Radiographic test Applicable; statement with the number, positions, shapes and sizes of pores, shrinkage cavities and
comparable defects possible. Test technique according to DVS 2206, Section 3.5.

Ultrasonic test Applicable to PE-HD, with restrictions to PP (statement about voids, not about quality). Test technique
according to DVS 2206, Section 3.4.

Pressure test Application usually for pipelines; test conditions according to the Pressure Device Directive. Test execution
according to DVS 2210-1, Supplement 2 and DIN 4279-7. Meaningfulness: leak tightness, experimental
evidence of the operational safety.
Destructive tests
Visual inspection of Formation of the executed weld cross-section (weld geometry), internal findings according to DVS 2202-1,
the weld cross-section Tables 4 and 5. Fracture pattern of the weld destroyed in the tensile test or in the technological bending
test.
Tensile test Execution according to DVS 2203-2: short-time tensile welding factor; DVS 2203-4: creep rupture welding
factor; minimum requirements according to DVS 2203-1. Test not applicable to fillet and single-bevel butt
welds.
Technological bending Execution according to DVS 2203-5, minimum requirements (bending angle) according to DVS 2203-1.
test Test not applicable to fillet and single-bevel butt welds.

The visual inspection concentrates, in particular, on the weld
shape, the notch-free surfaces and peripheral zones, the
optimum weld filling, the full weld penetration on the root side and
the joining part misalignment.
With ultrasonic and X-ray testing (see the DVS 2206 technical
code), flaws can be detected in the interior of the welds without
any destruction. However, on their own, they do not provide a
sufficient indication of the quality of the welded joint. Moreover,
the utilisation possibilities of these test procedures are limited
with regard to the weld geometry and the weld thickness.
For the designation and evaluation of defects, reference is made
to the DVS 2202-1 technical code.
It is necessary to stipulate the type and scope of the tests to be
performed in each individual case.
Material-specific tests are indicated in DVS 2201-1 and general
tests such as dimensional accuracy or surface assessment in
DVS 2206.
11 Safety instructions
Hazardous decomposition products and health-endangering
fumes result from the overheating of some materials (such as.
PVC, PVDF and E-CTFE) or already develop during the welding
of other materials (such as FEP, MFA, PFA and PTFE). On the
basis of the DIN safety data sheets to be submitted by the
manufacturer, the contractor must elaborate operating
instructions which comply with Section 20 of the Hazardous
Substances Ordinance (GefStoffV) and indicate all the potential
hazards and necessary protective measures. It may be
necessary to take further specific protective measures in each
individual case.
In explosion-protected areas, attention must be paid to the valid
safety regulations with regard to the welding work and any
measures which may be necessary must be agreed on with the
safety officer responsible; in this respect, see the Operational
Safety Ordinance (BetrSichV).
12 Standards and technical codes which are also
applicable
DIN 1910-3 Welding of plastics – Processes
DIN V 4279-7 Internal pressure testing of pressure piping for
(preliminary water – Pressure pipes made of low-density
standard) polyethylene PE-LD, pressure pipes made of
high-density polyethylene PE-HD (PE 80 and
PE 100), pressure pipes made of cross-linked
polyethylene PE-X and pressure pipes made of
unplasticised polyvinyl chloride PVC-U
DIN 16960-1 Welding of thermoplastics – Principles
DIN 32502 Defects in welded joints made of plastics –
Classification, designations and explanations
DIN EN 12943 Welding fillers for thermoplastics – Scope of
application, marking, requirements and testing
DIN EN ISO Plastics – Code letters and codes – Part 1: Base
1043-1 polymers and their particular properties
DVS 2201-2 Testing of semi-finished products made of
thermoplastics – Weldability – Test procedures
– Requirements
DVS 2202-1 Defects in welded joints between thermoplastics
– Characteristics, description and evaluation
DVS 2203 Testing of welded joints between panels and
pipes made of thermoplastics

361
Page 8 to DVS 2207-4

-1 Test procedures – Requirements DVS 2207-4, Welding of thermoplastics – Extrusion welding

-2 Tensile test Supplement 2 of pipes, piping parts and panels –
Requirements on the welding machines and
-4 Tensile creep test welding devices

R&D INTAKE MANIFOLDS

-5 Technological bending test DVS 2207-11 Welding of thermoplastics – Heated tool welding
DVS 2205 Calculation of tanks and apparatus made of of pipes, piping parts and panels made of PP
thermoplastics DVS 2207-15 Welding of thermoplastics – Heated tool welding
-3 Welded joints of pipes, piping parts and panels made of PVDF
-4 Flanged joints DVS 2210-1 Industrial piping made of thermoplastics –
-5 Rectangular tanks Planning and execution – Overground pipe
systems
DVS 2206 Testing of components and structures made of
thermoplastics DVS 2211 Welding of thermoplastics – Welding fillers –
Marking, requirements and tests
DVS 2207-1 Welding of thermoplastics – Heated tool welding
of pipes, piping parts and panels made of DVS 2212-1 Qualification testing of plastics welders –
PE-HD Qualification Test Groups I and II – Hot gas
welding with the torch separate from the filler
DVS 2207-3, Welding of thermoplastics – High-speed hot gas rod, high-speed hot gas welding, heated tool
Supplement 1 welding and hot gas welding with the torch butt welding, sleeve welding with an
separate from the filler rod of pipes, piping parts incorporated electric heating element, heated
and panels – Welding parameters tool sleeve welding and hot gas extrusion
DVS 2207-3, Welding of thermoplastics – High-speed hot gas welding
Supplement 2 welding and hot gas welding with the torch DVS 2225 Joining of sealing sheets made of polymer
separate from the filler rod of pipes, piping parts materials in earthwork construction and water
and panels – Requirements on the welding engineering
devices and accessories
DVS 2207-4, Welding of thermoplastics – Extrusion welding DIN standards can be obtained from Beuth Verlag, Berlin and
Supplement 1 of pipes, piping parts and panels – Welding DVS technical codes from Verlag für Schweißen und verwandte
parameters Verfahren DVS-Verlag GmbH, Düsseldorf.

362

Appendix 1: Brief instructions for the welding
1. Put together the welding equipment (Section 8.1)
R&D INTAKE MANIFOLDS
– valid welder's certificate
– hot gas extrusion welding device corresponding to the welding
job, including the operating instructions
– possibly hot gas welding device for tacking the joining parts
– welding shoes according to the weld shape
– flow meter for welding gas
– temperature gauge with sensors for measuring the hot gas and
the extrudate as well as the temperature of the semi-finished
products
– suitable measuring instruments for checking the misalignment,
the diameter and the thickness
– storage space for the devices
– scraper and scraper blade
– personal protective equipment
– dust protection for the welding wire
– cleaning agent
– Supplement 1: Welding parameters
– Appendix 2: Welding record sheet
– special welding instructions
2. Check the working conditions and plan the measures
(Section 8.2)
– accessibility
– sufficient lighting
– protective tent
– heating
3. Check the weldability (Section 6.4)
– on the semi-finished products and welding fillers, check that
the information from the manufacturers is correct
– check the condition and cleanness of the joining partners and
possibly clean them
– if necessary, check the weldability of the joining partners by
means of build-up welding according to DVS 2201-2 or trial
welds
Page 9 to DVS 2207-4
4. Prepare the welds and the joining faces (Section 9.1)
– check, stipulate and manufacture the weld geometry and the
weld shape
– remove the oxide layer from the joining faces by means of
chip-producing machining
5. Tack the joining parts (Section 9.2)
– execute a partial or continuous root layer with a hot gas
welding device
6. Start up and prepare the welding extruder (Section 7)
– check the supply lines (electricity and air) for any possible
hindrances to the welding operation
– connect and start the extruder according to the operating
instructions
– select, adjust and assemble the welding shoe and the hot gas
nozzle according to the weld geometry and the weld shape
– extrude the reheated welding filler out of the cylinder
– set and check the parameters (Appendix 1)
– preheat the welding shoe
7. Welding (Section 9.3)
–- check that the base material is sufficiently plastified (e.g. by
pricking it with a blunt tool)
– check the welding speed and monitor the uniformity
– continuously check the guidance of the welding extruder and
make any corrections needed
– if necessary, prevent any excessively rapid cooling of the weld
surface by covering it
– bevel the ends of the welds before restarts
– protect the welding filler from contaminations
8. Finish-machine the weld (Section 9.4)
– let welded parts cool down sufficiently before unclamping them
and subjecting them to loads
– machine off the lateral weld flow and the weld reinforcements
9. Compile the welding record sheet (Section 9.6)
–- fill in the welding record sheet (Appendix 2) and carry out the
visual inspection according to DVS 2202-1
363
364
Extrusion welding of panels and pipes Company logo

Project: Project no.: Protective

Weathering
measures
Drawing no.: Base material (manufacturer, type, batch, date):
1 = Sunny 1 = None

Welder: Welding filler (manufacturer, type, batch, date):

Page 10 to DVS 2207-4

2 = Dry 2 = Screen

Welding certificate no.: / valid untel Welding machine, make, tpye:

3 = Precipita- 3 = Tent
tion

Welding supervisor (3): Year of construction / last machine examination: Process variant according to DVS 2207-4:
4 = Wind 4 = Heating

Date Weld no. Joining part Weld shape Welding Air volume Material Hot gas Welding Ambient tem- Semi-finis- Weathering Protective Visual
thickness (symbol) shoe no. temperature temperature speed perature hed product (code no.) measures evaluation
temperature (code no.)
mm l/min C (1) C (2) cm/min C C
Appendix 2: Welding record sheet for the extrusion welding

(1) Measured with a pricking thermometer at the extrudate outlet of the welding machine / welding device Remarks: e.g. less favourable conditions
(2) Measured in the middle of the nozzle outlet opening, 5 mm in the nozzle
(3) E.g. specialist for plastics welding according to DVS 2213
R&D INTAKE MANIFOLDS

Date / signature of the welder Date / signature of the welding supervisor

 Draft May 2009

Welding of thermoplastics
DVS – DEUTSCHER VERBAND
Extrusion welding of pipes,
FÜR SCHWEISSEN UND Technical Code
VERWANDTE VERFAHREN E.V.
piping parts and panels DVS 2207- 4
Welding parameters Supplement 1
R&D INTAKE MANIFOLDS Comments until August 31, 2009

Planned as replacement for June 2006 edition

This draft is presented to the public for examination and comments. Proposals for additions or modifications should be sent to DVS
e. V., P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, before the date mentioned above.

This supplement to the DVS 2207-4 technical code includes guide values for the parameters for hot gas extrusion welding. They apply
to manual welding with the machines and devices specified in the DVS 2207-4 technical code, Supplement 1, and to the materials
listed in the table.
If necessary, other parameters may also be used for the welding with automatic welding machines (see Section 9.3).
By coordinating the hot air temperature, air volume and welding speed parameters, it must be guaranteed that the joining parts are
plasticised at the joint and down to a depth of 0.5 - 1 mm beyond the weld width (see Section 9.3).

Materials Abbreviations Material temperature 1) Hot gas temperature 2) Hot gas quantity 3)
°C °C l/min
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

High-density polyethylene PE-HD 4) 210 … 230 210 … 300 300

Polypropylene, Types 1, 2 and 3 PP-H; PP-B; PP-R 210 … 240 210 … 300 300
Unplasticised polyvinyl chloride PVC-U 190 … 200 330 … 360 300
Impact-resistant polyvinyl chloride PVC-HI 170 … 180 280 … 340 300
Chlorinated polyvinyl chloride PVC-C 195 … 205 300 … 360 300
Polyvinylidene fluoride PVDF 240 … 260 280 … 350 300

1) Measured with an insert thermometer at the extrudate outlet of the welding machine.
2) Measured 5 mm in the nozzle, in the centre of the nozzle opening.
3) Drawn-in cold air volume at the ambient pressure.
4) PE 63, PE 80 and PE 100.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group “Joining of Plastics”

Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

365
 File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-4\englisch\Jan_08\e2207-4bb2.fm
Erstellt am: 17.01.2008
Zuletzt geändert am: 29.01.2008

March 2008

DVS – DEUTSCHER VERBAND

Welding of thermoplastics
FÜR SCHWEISSEN UND
Extrusion welding Technical Code
VERWANDTE VERFAHREN E.V. of pipes, piping parts and panels DVS 2207-4

R&D INTAKE MANIFOLDS

Requirements on the welding machines and welding devices Supplement 2

Translation of the German version from april 2005

Contents: - the preheating of cooled extrudate at the outlet of the material

nozzle is ensured by suitable devices, e.g. baffle nozzle for the
1 Scope of application hot gas flow
2 Requirements
- they can be put down in a stable position at the end of the
2.1 General requirements
welding work or during interruptions in the work
2.2 Marking and documentation
2.3 Safety requirements
2.4 Plastifying system 2.2 Marking and documentation
2.5 Preheating system The following information must be permanently displayed on the
2.6 Welding shoes machines and devices:
2.7 Accessories for discontinuous welding
3 Standards and technical codes which are also applicable – information about the manufacturer and the type
4 Literature – information about the electricity supply, the power input and
the frequency
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

1 Scope of application – identification number

This supplement to the DVS 2207-4 technical code describes
general, qualitative and safety-relevant requirements on ma-
chines and devices for the extrusion welding of thermoplastics.
It applies to the Machine Variants I, II and III specified in the
DVS 2207-4 technical code and should ensure that the quality of
the welds which is demanded in the technical code is achieved
when the devices and machines are operated and handled
properly.
2 Requirements
2.1 General requirements
The machines and devices must guarantee that:
– the functioning capacity is ensured within the intended temper-
ature utilisation range from - 5°C to + 60°C
– the storage within a temperature range from - 20°C to + 80°C
does not cause any damage
– the mechanical stresses occurring during proper transport and
operation do not lead to any disturbances or damage
–- the internal surfaces and the screw have sufficient corrosion
protection against externally effective humidity as well as
against the planned welding filler or its constituents
– the machine and device elements are ergonomically designed
according to their intended application and handling and can
be operated easily and safely
– all the components and functional elements must be easily ac-
cessible for the intended operation as well as for the necessary
cleaning and maintenance
– the required joining pressure can be applied in the planned
welding positions using corresponding holding jigs and han-
dles
– the design of the supply hoses and cables is flexible and force-
saving for the welder so that it neither kinks nor twists during
proper operation
– CE symbol and protection class
All the machines and devices are provided with operating and
maintenance instructions which, at least, must include the
following:
– functional description with operating instructions
– information about the application range (power range)
– maintenance schedule with information about the test cycles
– service addresses
It is recommendable to compile a list of any possible malfunc-
tions, including any possible causes of defects and information
about how to rectify them.
2.3 Safety requirements
The machines and devices must not involve any risk of injury
whatsoever for the user when they are utilised properly.
In particular, the following is applicable:
– any surfaces which become hot must be kept as small as pos-
sible and, wherever technically possible, insulated
– any parts close to the welder's hands must not exceed opera-
tionally induced temperatures of 40°C, even in the case of
lengthy utilisation
–- sharp edges on the machines, devices and accessories are
not permissible
The machines and devices must comply with the applicable
regulations and technical codes.
2.4 Plastifying system
The following requirements must be met:
Uniform welding filler supply adapted to the screw speed in all the
planned welding positions.
In order to interrupt the granule supply, a suitable barrier must be
provided in the corresponding machines or devices.

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.

DVS, Technical Committee, Working Group “Joining of Plastics”

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

366
Page 2 to DVS 2207-4 Supplement 2
If the material temperature and, wherever integrated by means of
appliance engineering, the hot gas temperature move above or
below the stipulated tolerance limits, an automatic drive cut-off
and overtemperature protection must take effect.
R&D INTAKE MANIFOLDS
The material output above 1.5 kg/h should be infinitely adjustable
on the machine or device with the aid of the screw speed.
Constant speeds are permissible in the case of machines and
devices which are used exclusively for discontinuous welding.
A drive cut-off must be effective for the heating-up time of the
welding filler which has cooled in the extruder and in the supply
hose.
The interruption switch (on/off) for the plastifying system must be
arranged in such a way that it can be operated by the welder at
any time. This also applies to the material temperature controller.
The extrudate must be plastified in a completely homogeneous
form and must emerge with a constant material output at a stable
temperature.
The material temperature at the material outlet must be dis-
played.
The temperature fluctuation of the material must not exceed
± 3 K (measured in the centre of the material) in continuous
operation and with an unchanged controller setting.
The deviation between the temperature set on the controller and
the actual outlet temperature must not exceed ± 10 K.
The following applies to machines and devices which are used
exclusively for discontinuous welding:
– The material nozzles must be easy to replace.
– The nozzle cross-section must correspond to the weld volume
to be filled in each case.
2.5 Preheating system
The preheating system must guarantee that the weld sidewalls,
the weld overlap and the weld root are plastified sufficiently. This
may be achieved with various systems, e.g. by hot gas heat or
radiant heat. Because of the practical application, only the
preheating by means of hot gas is dealt with below.
– The hot gas temperature is infinitely adjustable, according to
the material to be welded, and is displayed. The temperature
fluctuation at an unchanged controller setting must not exceed
± 10 K. The welding gas temperature must be reached after
max. 15 min.
– The hot gas nozzles must be provided with a test borehole
which permits reproducible measurements of the temperature
according to DVS 2207-4. The transferability of the measured
temperature values to the stipulations in the DVS 2207-4 tech-
nical code, Supplement 1 must be guaranteed – if necessary,
by means of conversion tables.
– The volume flow must be min. 300 I/min (cold air volume in-
take at the ambient pressure) and must be kept constant
during the welding operation.
– The heating unit is firmly installed on the welding head or on
the plastifying system. In the case of machines and devices
which are used exclusively for discontinuous welding, the heat-
ing unit is guided independently of the plastifying system.
– The hot gas nozzle must guarantee the intensive and uniform
preheating (plastification) of the base material across the
entire weld width – at the lowest possible hot gas temperature.
Table 1 shows an example of a nozzle geometry. The nozzle
cross-sections specified in the table guarantee the reliable
overlapping of the different weld geometries and weld widths [1].
In the case of larger welding groove widths, the existing basic
geometry must be correspondingly enlarged to scale.
In the case of machines and devices which are used for
discontinuous welding, the nozzle must be easy to change.
Table 1. Examples of the welding nozzle geometry and the air outlet
cross-sections for weld widths up to 40 mm.
Shape of nozzle Seam Dimensions
width x1)
(air outlet opening) of nozzle
(mm) (mm)
a b
Up to 15 8 18
16 ... 20 10 23
21 ... 30 12 34
31 ... 40 15 50
maximum welding groove width
2.6 Welding shoes
The welding shoes must comply with the stipulations in the
DVS 2207-4 technical code, Section 6.2.
The safe and secure coupling as well as the easy replacement of
the welding shoe must be guaranteed (this does not apply to
devices which are used exclusively for discontinuous welding).
2.7 Accessories for discontinuous welding
The press-on tools used for discontinuous welding must
guarantee the most uniform possible input and pressing-on of the
extrudate. The radius of the press-on surface with a bend length
of 120 - 130 mm is approx. 100 mm. The width of the press-on
surface corresponds to the weld width. The edges of the press-
on surface must be rounded. If necessary, special press-on tools
are necessary for particular weld geometries.
The quiver consists of a PTFE pipe with a handle which closes
the pipe on one side. The inside diameter of the pipe is adapted
to the welding filler to be accommodated.
3 Standards and technical codes which are also applicable
DIN EN ISO 12100-1 Safety of machines – Basic terms and
general guiding principles for design –
Part 1: Fundamental terminology and
methodology
DIN EN ISO 12100-2 Safety of machines – Basic terms and
general guiding principles for design –
Part 2: Technical guiding principles
DIN EN 55014-1 Electromagnetic compatibility – Require-
ments on household appliances, power
tools and similar electrical appliances –
Part 1: Interference emission
DIN EN 55014-2 Electromagnetic compatibility – Require-
ments on household appliances, power
tools and similar electrical appliances –
Part 2: Interference immunity
DIN EN 60204-1 Safety of machines – Electrical equip-
ment of machines – Part 1: General re-
quirements
DIN EN 61000-3-2 Electromagnetic compatibility (EMC) –
Part 3-2: Limiting values – Limiting val-
ues for harmonic currents (appliance in-
put current: 16 A per conductor)
DIN EN 61000-3-3 Electromagnetic compatibility (EMC) –
Part 3-3: Limiting values – Limitation of
voltage changes, voltage fluctuations
and flickers in public low-voltage supply
grids for appliances which have a rated
current of 16 A per conductor and are not
subject to any special connecting condi-
tions
367
 Page 3 to DVS 2207-4 Supplement 2

DIN EN 60335-1 Safety of electrical appliances for domes-

tic use and similar purposes – Part 1:
General requirements

R&D INTAKE MANIFOLDS

DIN EN 60335-2-45 Safety of electrical appliances for domes-
tic use and similar purposes – Part 2-45:
Particular requirements on non-station-
ary electrical heating tools and similar
devices
DVS 2207-4 Welding of thermoplastics – Extrusion
welding of pipes, piping parts and panels
– Processes and requirements
DVS 2207-4, Welding of thermoplastics – Extrusion
Supplement 1 welding of pipes, piping parts and panels
– Welding parameters
EC Machine Directive 89/392; 2nd Amendment of 91/368
EEC; 3rd Amendment of 93/44 EEC
VBG 22 Working machines in the chemical, rub-
ber and plastics industries (now only
applicable to stocks of old machines)

4 Literature

[1] Gehde, M.: About the extrusion welding of polypropylene.

Doctoral dissertation, University of Erlangen-Nuremberg, 1993.

368
 Erstellungsdatum: 04.11.1999
Letzte Änderung: 13.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-05\englisch\e2207t5.fm

Directive D
DVS – DEUTSCHER VERBAND Welding of Thermoplastics –
DVS 2207-5
FÜR SCHWEISSEN UND Welding of PE Casing Pipes, V
VERWANDTE VERFAHREN E.V. Tubes and Tubular Components (Februar 1993) S 
R&D INTAKE MANIFOLDS
Contents: – Permanent mechanical joint under thermal load resulting from
the temperature of the medium under simultaneous external
1 Scope and internal mechanical load.
2 General requirements imposed on welded joints
– Permanent watertight joint of the PE-HD casing in all operating
3 Material
conditions and load cases.
4 Types of execution of welded joints on PE-HD casing pipes
4.1 Casing pipe/Sleeve joints – Transition of the forces acting on the sleeve into the casing
4.2 Welds on fittings pipe, caused for example by the increased resistance of the
5 Carrying out the welding process soil pressure in the sliding region. The increased soil
5.1 Heated plate welding (HS) resistance results from the thermal expansion of the moving
5.2 Hot gas extrusion welding (WE) long distance heating piping, when the largest sleeve diameter
5.3 Electrofusion (HM) exceeds the diameter of the casing pipe.
5.4 Indirect heated tool sleeve welding (-)
5.5 Hot gas welding (W)
6 Testing the welded joints 3 Material
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

6.1 Tensile test

6.2 Technological bend test The material to be used for the casing pipe, for sleeves and
6.3 Manual peel test fittings and if necessary the welding filler is PE-HD DIN 8075 –
6.4 Tensile creep test with the strength properties in terms of creep behaviour
6.5 Imperviousness test corresponding to the State of the Art (as dealt with in Section 8.3
7 Requirements imposed on welded joints of this Directive). In order to ensure weldability, the parts to be
7.1 Visual examination welded and if necessary the welding filler materials used must
7.2 Mechanical-technological tests in the short-term test correspond to the melt index groups 005 and/or 0101) to DIN
16776 Part 1.
7.3 Tensile creep test
7.4 Imperviousness test
8 Quality Assurance 4 Design versions of welded joints on PE-HD casing pipes
8.1 Quality Assurance for casing pipes and fittings in the Manu-
facturer's Works Forms of application of welded joints are found as tube/sleeve
8.2 Proofs of Quality for casing pipes and fittings joints and in the manufacture of fittings. The tube/sleeve joints
8.3 Quality Assurance of the welding work are welded on site, welds on fittings are produced both on site
9 Standards, Directives and also in the works.
9.1 Standards
9.2 Directives 4.1 Tube/Sleeve joints
Annex 1 Report Form (Proposal) for electrofusion methods
Annex 2 Report Form (Proposal) for heated plate welding 4.1.1 Heated plate welding (HS)
Annex 3 Report Form (Proposal) for extrusion welding
Heated plate welding2) is used in the works for producing fittings.
Annex 4 Report Form (Proposal) for imperviousness test
For reasons of design this method is not customary for tube/
Annex 5 Test content and implementing internal and external
sleeve joints.
monitoring
Annex 6 Determination of the time factor and a fictitious joining
4.1.2 Extrusion welding (WE)
factor for a welded joint
Annex 7 Stressing of KMR welded sleeves In extrusion welding the two weld shapes V-weld and fillet weld
are produced. Extrusion welding is customary both for the
manufacture of fittings in the works and for tube/sleeve joints.
1 Scope
4.1.2.1 Butt weld with V-weld, Fig. 1.
The Directive applies to all PE-HD welds on components of
plastic casing pipe systems. These include in particular the joints The sleeve tube, which has the same outside diameter as the
of the PE casing pipes and elbows, T-pieces, reducers and casing pipe, is placed slotted in the longitudinal direction over the
special parts with sleeves. The guideline is applicable both to casing pipe. The sleeve tube is fitted with saw cuts on both sides
welds made in the works and for welds which are carried out on and the butt bevel preparation made. Then the circular seams
site. are welded and finally the longitudinal seam. The welding of the
circular seams is done by extrusion welding with a trolley which is
rotated around the tube on a special strap. Particular care must
2 General requirements imposed on welded joints be taken when making the butt region between the circular
seams and the longitudinal seam. Suitable welding shoe shapes
The following general requirements are imposed on the welded for V- welds, matched to the seam shape, must be used (see Fig.
joint: 1).

1) Melt index group 005 = MFI 190/5 = above 0.4 to 0.7 g/10 min. Melt index group 010 = MFI 190/5 = above 0.7 to 1.3 g/10 min.
2) Formerly called "Spiegelschweißen" ("mirror welding")

This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.

DVS, Technischer Ausschuß, Arbeitsgruppe "Fügen von Kunststoffen"

in common with Arbeitsgruppe "Schweißen von PE-Mantelrohren" der Arbeitsgemeinschaft Fernwärme – AGFW – e.V.
bei der Vereinigung deutscher Elektrizitätswerke

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

369
Page 2 to DVS 2207-5

Detail “X” accordance with the seam shape is to be used (see Fig. 5b).
V-weld, extrusion
welding with filler 4.1.3 Electrofusion

“X” In the application electrofusion is used with integrated heating

R&D INTAKE MANIFOLDS conductors.

4.1.3.1 Sleeve tube/Plate with built-in heating conductors for longi-

tudinal and circumferential welds, Fig. 3
With this method the sleeve tube is made in the works from a
sleeve tube/plate provided with heating conductors. For the
longitudinal seam a supporting element is incorporated. Then the
tube or the plate is placed around the prepared ends of the
casing pipes and secured with external clamping rings. At the
same time the clamping rings serve to apply the compressive
Figure 1. Basic design of a fitted sleeve with V-welds. forces during electrical heating, which are necessary for the
welding. Lap welds are used for the circumferential and
longitudinal seams.
Detail “X” Fillet welds, extrusion
welding with filler 4.1.3.2 Sleeve band with built-in heating conductors for longitudinal
and circumferential seams, Fig. 4
A longitudinally slit sleeve tube is fitted between the ends of the
casing pipes with the same diameter. Over the joint grooves in
the circular butt joint region and on the longitudinal butt joint a
Profile ring “X” band provided with heating conductors is placed and fitted to an
external clamping device during the heating.

Detail “X” Band with heating conductor

Spacer/pressure support

Figure 2. Basic design of a slip-on sleeve with fillet weld. “X”

4.1.2.2 Lapp joint with fillet weld, Fig. 2.
In this case the sleeve tube is not divided. There is no
longitudinal seam. The circular seams are executed as fillet
welds as described under 4.1.2.1. For fixing and centering the
sleeve and for forming a reliable root a profile ring rounded
towards the seam (for example of plywood or plastic) is inserted.
For seam shape see DVS 2209, Fig. 10, or Fig. 5b). Care must
be taken to ensure adequate overlap of the ends of the casing
pipes (make markings).
The execution of the extrusion welding takes place as described
under 4.1.2.1. A welding shoe for this fillet weld design shaped in Figure 4. Basic design of a welding sleeve with sleeve band.

Detail “X” Sleeve tube/plate

Heating conductor

Casing pipe

“X”

Figure 3. Basic design of a welding sleeve with a longitudinally slit sleeve tube or a sleeve plate.

370

4.1.3.3 Slip-on sleeve with built-in heating grids
For this variant, basically the same welding principle is used as
for the variants with heating conductors built into the sleeve tube
parts in the works, as described above. The essential difference
R&D INTAKE MANIFOLDS
is that the surface areas of casing pipe and sleeve must be
prepared and the heating conductor band only applied and fixed
in the sleeve joint on site. Furthermore, the diameter difference
existing between the casing pipe and the sleeve must be formed
by hot forming before the welding process. Sleeve and butt joint
shape as in Fig. 3, but without longitudinal seam.
4.1.4 Indirect heated tool welding
In this welding process the heat energy necessary for the welding
is supplied through the tube joint to the welding plane by
conduction from a heating band placed on the outside of the
sleeve joint and used as a ring clamping element. As a result the
diameter distance existing between the casing pipe and the
sleeve tube is overcome during the welding process by shaping
the sleeve on to the casing pipe when the material is in the
thermoplastic state.
4.2 Welds on fittings
Basically the various designs of bends and T-pieces used are
mainly manufactured or prepared in the works. Making fittings on
site is to be avoided, because the conditions are less favourable.
4.2.1 Bends
4.2.1.1 Finished bends
The PE casing pipe of the bend is manufactured from tube
segments in the manufacturer's works by heated plate welding.
4.2.1.2 Assembly bends
In order to equip bends on site with the PE-casing outside the
prefabricated angle range also, prefabricated assembly bends
are used. For this the PE segment bends are longitudinally split
on the site, so that the part can be placed around the steel piping.
The longitudinal cut is welded in the site trench. For this purpose
extrusion welding should be used.
4.2.2 T-pieces
Branches for connecting lines from the main piping are called T-
pieces. The diameter ratios D1 to D2 are usually different.
Both T-piece designs with "outward necking" and heated plate
butt welding and designs which are produced by extrusion
welding are usual. Similarly, combined applications of these
welding processes are customary. In special cases the work also
takes place on site, as described under 4.2.1.2
4.2.3 Valves
PE casing pipe constructions of the most varied kind are
necessary for valves to be used in the soil, such as ball valves,
slide valves, butterfly valves or compensators. These
components are made in the works. The welding methods used
for installing them are heated plate butt welding and extrusion
welding.
4.2.4 Special fittings
For the PE casing pipe constructions of anchor points, reducers,
end caps and other parts, as far as possible components
prefabricated in the works by extrusion welding or heated plate
welding should be used.
5 Carrying out the welding process
In the PE casing pipe field of applications joints must be made
both by producing fittings in the works and also in the course of
the pipelaying work under site conditions – usually in trenches. In
order to achieve high quality welded joints, in addition to the
special preparations necessary for the individual working
methods the following conditions must be created, independently
of the method:
Page 3 to DVS 2207-5
– The manufacturer's documentation must include detailed
working instructions for the welding method used and in
particular indicate the welding parameters (guide value tables).
– The welding area must be protected against environmental
conditions, such as moisture, wind and dust, strong solar
radiation and temperatures below + 5°C. The formation of frost
and moisture film must be prevented.If welding work has to be
carried out under unfavourable conditions, suitable protective
measures must be taken in good time, such as for example
covering, preheating of the pipe joints and sleeve parts,
erection of a protective tent, if necessary with heating.
– An even temperature must be maintained in all parts to be
welded and also around the tube circumference (∆T < 20 °C).
– The welding areas must be cleaned (in the case of traces of oil
and grease with suitable solvents, for example industrially pure
spirit), and the surface oxidized by the oxygen of the air must
be removed, for example by planing, scraping, milling. If wire
brushes or emery cloth are used care must be taken to ensure
that even removal of the surface layer around the
circumference is achieved, no dirt particles are "rubbed in" and
abraded residues are thoroughly removed (blowing, brushing
clean etc.). The tools used must be kept clean and free of
grease and must be checked and if necessary cleaned before
use.
– Sleeve parts with incorporated heating conductors must be
supplied to the welding site in their packing and before welding
the surfaces to be welded must be cleaned, for example with
industrially pure spirit.
– The cleaning and machining of the welding planes or welding
surfaces must take place immediately before the welding. The
machined surfaces must be protected against further
contamination and may not be picked up again. Otherwise
repeated machining is necessary.
– Adequate working space must be made around the welding
site, so that the particular welding process can be carried out
reliably.
– The tube joints, fittings, sleeve parts, etc., must be supported,
aligned and fixed securely in the intended position.
– The welding work must be carried out and monitored by
qualified welders (see Section 8.3). It is recommended that
meaningful work reports be prepared concerning the welded
joints (for report form suggestions see Annex) and the joints
permanently marked.
– The welded joints may only be subjected to load after cooling
to ambient temperature.
The preparations and conditions specific to each welding process
and the execution of the welding processes are described below.
5.1 Heated plate welding (HS)
This welding method is used in the case of PE casing pipe
exclusively for manufacturing tube bends and other prefabricated
fittings in the works. The preparation and execution of the
method and the requirements imposed on the welding machines
used are governed by the stipulations in the Directives DVS 2207
Part 2 and DVS 2208 Part 1.
5.2 Hot gas extrusion welding (WE)
Of the process variants described in Directive DVS 2209,
Variants II and V are mostly used in modified, partially
mechanized versions.
With process variant II, using a hand instrument, longitudinal
seams on fitted sleeves are welded. Also in the case of repair
work, if sleeves tubes have to be installed later, i.e. they must be
previously split longitudinally for fitting and welded in the
installation position by butt welding with a V-seam. Furthermore,
these manual process variants are used for auxiliary welds in
regions near to fittings and the like which cannot or can only with
difficulty be reached by machines.
371
Page 4 to DVS 2207-5

For welding sleeve circumferential welds as per Variant II circumferential welds in the region at the beginning of the weld)
partially mechanized equipment is used. To reduce the and after welding over with the welding unit tilted forwards the
necessary working space the welding machine is arranged in a material being welded must be held with a hand plunger.
narrow angular position with respect to the tube axis and

R&D INTAKE MANIFOLDS

equipped with a suitably matched angular welding shoe – and is – Ejected accumulations must be removed down to "healthy"
carried in a manually operated trolley running on rollers in an weld (notch-free rounded shaving).
orbital frame around the tube circumference. To ensure reliable
guidance and better matching of the equipment speed of
advance to the other welding conditions, steplessly controllable
motor drives must be provided. The welding filler is fed in in wire
form, for example 4 mm diameter, from the supply unit Welding shoe
(encapsulated roll stands, if possible with preheating and drying
system). Melt channel

The heating of the welding zone is done by hot air. Adequate

plastication of the PE material beyond the side wall edges and in
the weld root region requires optimum adjustment of the hot air
nozzle to the joint to be welded (V or fillet welds, curvature of the
weld paths, joint width). The parameters, such as air volume/
temperature and welding speed, must be matched to the filler-
ejection power of the equipment.
The equipment Variant V in the version for casing pipe welding
differs only in the machine side plastication for the welding filler. a) Welding shoe for V-seam: joint opening approx. 60o
This works on the piston principle, in which the filler wire (smaller wall thickness to 80o (greater wall thickness)).
introduced – driven in the infeed region – acts as a consumable
piston to bring about the ejection of the plasticized filler in the x = 0, i. e. without gap, if welding is done without backing.
heated cylinder. All other conditions and functions are as x = 1 – 2 mm, if welding is done with backing.
described above.
In both process variants the plasticized welding filler is brought
Melt channel Welding shoe
into the joint groove by extrusion through the shaping "welding
shoe". In order to achieve adequate welding, i.e. adequate melt
pressure in the welding filler in the critical areas of the seam (root
and upper runoff edge), the welding shoe must have a front
"shoe tip" matched to the joint and adequate overlap length (Fig.
5). For the usual weld thickness in the range of applications up to
approximately 10 mm tube wall thickness an overlap/holding
length of 40mm after the runner is necessary.
The shoe shapes must be matched to the joint shapes depending
on the type of weld (overlapping butt-fillet weld) and the
curvatures to the necessary degree. The lateral sealing surfaces
together with the front "shoe tip" form the clamping for the
welding filler introduced by the extrusion and thus the condition
for the necessary pressure build-up in the weld material. These
Profile ring
sealing surfaces should be approximately 5 mm wide. All
transitions and edges must be carefully rounded, so that during
b) Welding shoe for overlapping butt fillet weld:
welding no plasticized compound is "shaved off" the joint side
The upper edge must also be bevelled with a negative angle
walls causing defects. For extrusion welding see DVS Directive
of up to 15o.
2207 Part 4.
The edges must always be rounded!
For the carrying out of the welding the following are necessary:
– A visible positioning and fixing of the parts to be welded
(casing pipe and tubular sleeve) in the intended butt weld Feed direction
shape; if necessary short tack welds in the weld root.
– Precise centering and adjustment of the orbital frame over the
course of the joint groove; therefore the machining of the joint
surfaces with tool systems must take place in the same frame Welding shoe
setting as the welding.
Melt channel
– Control and tracking systems for continuous adjustment of the
welding unit (direction and position of the welding shoe) and Tip of welding shoe
the hot air nozzle position (central in the median line of the joint
opening).
– Stepless speed adjustment of the welding carriage and control
by intensive observation of the welding point and/or the melt
delivery.
Butt weld side wall of a
– Monitoring of adequate joint heating directly in front of the V-seam in the tube joint
welding unit by penetration tests with blunt tools (thin
screwdriver). c) Welding shoe for V-seam in the middle of the seam
(lingitudinal cut)
– Correct execution of the end regions to be overlapped in the
case of circumferential welds and longitudinal welds. The Figure 5. Schematic drawings for executing weld sheos for extrusion
groove must be adequately bevelled (in the case of welding for V-seams and overlapping butt fillet welds.

372

5.3 Electrofusion *) (HM)
The process variants used in practice are based on sleeves or
sleeve plates with heating conductors with 3-sided conductor
arrangement incorporated in the works (additionally for the
R&D INTAKE MANIFOLDS
longitudinal seam), or use for the particular size inlaid heating
grids prepared in the works, which are mounted and fixed in the
lap joint on the casing pipe.
The requirements imposed on the welder in all process variants
essentially relate to careful execution under site conditions.
These are in particular:
– The preparation of the casing pipe joints,
– The correct assembly and fixing of the welding sleeves
including the clamping and holding systems and
– The making of the electrical connections to the welding
equipment.
With modern equipment the welding process itself is
automatically controlled on the basis of previous automated
actual value sensing of the critical initial values (such as
resistance as a measure of the sleeve nominal diameter, ambient
and component temperature) and automatically controlled as it
progresses on the basis of power consumption measurements.
After the equipment has been basically set the welder has only a
supervisory function during the welding process.
As far as equipment is concerned, with these methods the
systems must be equipped with measurement value sensing and
digital recording systems, so that each sleeve joint can be
documented with conclusive parameter and parameter change
reports.
5.3.1 Tubular sleeves/sleeve plates with built-in heating conductors
(cf. Sections 4.1.3.1 and 4.1.3.2)
In respect of the introduction of energy into the joint is concerned,
the prescribed welding parameters must be matched in particular
to the wall thicknesses, the semi-finished product and ambient
temperaures and the material melting characteristics. The
process must then be controlled with the pressure generating unit
for the welding pressure in system coupling. The welder on the
site cannot control the welding process, because with this weld
shape in the lap joint and with the superstructure formed by the
pressure generating devices he cannot look into the welding
plane and therefore any controlling influence over the welding
process is out of the question.
For reproducible reliable production of high quality welded joints
according to these process variants welding units with preset
parameters and process controls optimized for the particular
application are necessary. For the quality of the welded joints the
welding and supervisory personnel must correctly and carefully
create the external preconditions on the basis of the stipulations
of the process instructions. These are in particular the following
steps:
– Dimensionally correct marking of the sleeve position and/or the
welding regions.
– Trimming of the tube joints and fitting supporting sections for
the longitudinal welds.
– Machining of the tube surfaces in the weld regions, taking care
to avoid recontamination when the sleeve is subsequently as-
sembled (clean slip-on sleeves and casing pipes inside and
outside beforehand).
– Positioning and fixing of the tubular sleeves or sleeve plates -
in the predetermined position with rigid straps.
– Setting up the pressure generating devices and clamps.
– Making the electrical connections, and the pressure connec-
tions and control connections, followed by examination to
avoid confusion, and function monitoring of the welding ma-
chine.
*) DIN 1910 Part 3: “Sleeve welding with incorporated electric heating element”
Page 5 to DVS 2207-5
- Starting up and monitoring the welding process.
– Removing the welding pressure only after the welding zone
has cooled down sufficiently to approximately + 90 °C; indicati-
ons of the time for this must be taken from the process instruc-
tions of the manufacturer.
5.3.2 Slip-on sleeve with inlaid heating grid
(cf. also Section 4.1.3.3)
As far as the equipment is concerned, basically for this process
variant the same principles as described under 5.3.1 apply. In the
execution basically the following process-specific jobs must also
be carried out:
– Determining and marking the welding regions in the joint.
– Cleaning and machining both surfaces in the welding regions
(casing pipe and tubular sleeve).
– Adapting the heating grid strip to the tube circumference by ap-
propriate stretching, positioning of the strip and fixing accor-
ding to the manufacturer's instructions; take note of the alloca-
tion marking of the heating grid strips!
– Assembling the tubular sleeves in the predetermined position.
– Adapting the slip-on sleeves to the diameter of the casing pipe
by hot forming. The sleeve ends are heated evenly to the for-
ming temperature over an adequate width in the region of the
heating strips and clamping elements (approx. + 100 °C).
(Take care when using naked flame; use "soft" liquefied gas
flame). The adapting of the diameter is done by fixing the clam-
ping members and applying the pressure without delay. The
latter is used after starting the welding process for applying the
joining force.
The other functions and operations are the same as in the works
sequence previously described.
5.4 Indirect heated tool sleeve welding (–)
(cf. Section 4.1.4)
The heat input necessary for the welding of the lap joint on the
sleeve connection takes place indirectly by heat conduction
through the wall of the sleeve to the welding plane. The metal
heating strip applied to the outside of the sleeve joint is also used
through a hydraulic clamping system as an orbital clamping
element for applying the joining force for the welding.
According to the system the temperature profile across the
sleeve wall on the outside of the sleeve has a higher temperature
than the welding point on the inside; the profile of the melt
viscosity runs in the same way. Because the clamping ring
presses the sleeve joint over the entire plasticized sleeve wall the
heating strip is pressed into the tube wall, i. e. a "notch" is
produced by wall thickness reduction in the welding region.
During the welding process at the same time the annular gap
existing between the casing pipe and the sleeve tube is closed by
the clamping of the heating strip ring which causes thermoelastic/
plastic material deformation. The external step formation under
the heating strip position and the wall thickness reduction of the
sleeve in the weld region are forced to increase with the size of
the sleeve annular gap. For this reason the use of this process
variant is limited to small casing pipe diameters (at the moment
up to maximum 400 mm).
To what extent this "notch formation" which weakens the weld
start region is acceptable from a strength point of view must be
demonstrated for the particular application.
The energy supply of the welding equipment must be
programmed to the tube size and to the semi-finished product
and ambient temperatures. As far as the application of pressure
is concerned, the annular clamping system must be
synchronized with the heating process. The corresponding
information must be taken from the process instructions of the
system manufacturer.
The weld preparation and the other operations are subject to the
373
Page 6 to DVS 2207-5

Joining weld Joining weld

R&D INTAKE MANIFOLDS

Specimen Shape 1
(Strip specimen) Specimen Shape 2
(Shoulder specimen)

Figure 6. Specimen shapes for the tensile tests.

same basic stipulations and operational steps as described for short term strength the specimens are pulled at constant test
the process in Section 5.3. speed. For PE-HD the test speed is 50 mm/min.

5.5 Hot gas welding (W)

The method is described in Directive DVS 2207 Part 3. With the
method of hot gas welding with filler, for example hot gas string-
bead welding with welding wire – generally lower long-term weld
strengths are achieved than with the welding methods described
above. This is all the more so, if the welding work has to be
carried out under difficult conditions; on sites and mostly in
trenches in the case of circumferential welds.
For these reasons hot gas welding should not be used on lines
with PE-casing pipes.
If because of local circumstances this method cannot be avoided
in exceptional cases, particular care must be taken during
execution. The requirements of DVS 2203 Part 1 must be
fulfilled.
6 Testing the welded joints
For the testing of welded joints the test methods described in the
following can be used, taking into account the requirements
imposed and/or the conclusions required.
The results of the short term tests however can only be
transferred to the long term behaviour of the welded fabrication to
a limited extent. Specific demonstrations of the long term
behaviour are only possible by means of long term tests.
Generally the specimens must be manufactured by sawing,
milling or water jet cutting (not stamping).
6.1 Tensile test
The force at the moment the specimen tears must be recorded. If
the specimen should neck, this yield stress is the reference
stress (FB). Tests during which the specimens tear in the
clamping region should be disregarded and must be repeated.
6.1.2 Evaluation
For the welded specimens FV and the unwelded specimens
(reference specimens) FB the short term joining factor fz = FV/FB
is determined from the mean values of the tearing force, in the
case of different specimen dimensions, from the stresses
referred to the specimen cross-section.
6.2 Technological bending test
For assessing the execution of the weld the technological
bending test in combination with other tests can be used. The
bending angle and the fracture photomicrograph give an
indication of the deformability of the joint and thus of the quality of
the execution.
The bending test is carried out on the basis of the Directive DVS
2203 Part 5 and/or DIN 50 121. The bead is machined away in
the region where the bending punch is applied. The edges on the
tensile stressed side must be broken. Six welded specimens are
tested. The tensile stress is applied both to the root and to the
overlay of the welded joint (3 specimens each).
Information about the shape and the dimensions of the
specimens and the test arrangements is contained in Table 2.
Table 2. Dimensions for the test arrangement for the technological
bending test (from DVS 2203 Part 5).

The tensile test is carried out in accordance with DIN 53 455 or Specimen Supporting Bending beam
DVS 2203 Parts and 1 and 2. The welded joints are tested in Thickness Width Length width thickness
accordance with the actual execution, i.e. with or without bead. h LS d
The joint lies in the middle of the specimen. At least 6 welded and
6 unwelded specimens (reference specimens) are tested. 3<h≤5 20 150 80 4
5 < h ≤ 10 20 200 90 8
If the strip specimens of Shape 1 to Fig.6 tear in the clamping 10 < h ≤ 15 30 200 100 12,5
region, specimens of Shape 2 must be used. The dimensions of 15 < h ≤ 20 40 250 120 16
the particular specimen shape should be taken from Table 1. 20 < h ≤ 30 50 300 160 25

Table 1. Dimensions of the specimens for the tensile test. On smaller tubes if necessary a smaller specimen diameter
In the case of lap welded joints the dimensions L and Lf must be should be chosen. However, 15 mm should be the minimum.
increased by the welded overlap length.
6.2.1 Execution
Thickness Specimen Shape 1 Specimen Shape 2
h Unless agreed otherwise, this test is carried out at room
b Lf L b Lf L be
temperature (+ 23 °C ± 2 °C). The specimens of PE-HD are bent
< 10 15 120 ≥ 170 10 115 ≥ 170 20 in the test rig at a test speed of 50m m/min until fracture/incipient
> 10 30 120 ≥ 300 30 115 ≥ 300 40 tearing. The arrangement of the bending beam should be taken
> 20 1,5 h 200 ≥ 400 1,5 h 200 ≥ 400 80 from Fig. 7 for the various design versions of the joints.
The bending angle reached on incipient tearing or fracture is
6.1.1 Execution
measured. Complete bending of the specimen, without tearing or
Unless agreed otherwise, the test is carried out to DVS 2203 Part fracture, corresponds to a bending angle of 160° and is to be
2 at room temperature (+ 23 °C ± 2 °C). For determining the evaluated as > 160°.

374

R&D INTAKE MANIFOLDS a)
b)
“X”
c)
d)
Detail “X”
Groove 1 mm deep,
4 mm wide
Figure 7. Diagrammatic representation of the mechanical test and the
planes of action in the technological bending test (examples):
a) V-weld, root as tension side
b) V-weld, rear of weld under tension; during the test at a
bending angle of approximately 90o,
c) and d) die arrangement for the lap welded joint with fillet
weld (WE). 3 specimens each with the weld root (c) and
the joint side wall edges (d) under tension.
6.2.2 Evaluation
The technological bending test does not supply mathematical
values for the design calculations. On the basis of the deformati-
on behaviour determined and the fracture photomicrograph the
results however allow a general qualitative assessment of the
joint to be made.
For a general good/bad assessment the minimum requirements
indicated in Fig. 14, Section 7, of Directive DVS 2203 Part 1 can
be taken as the basis.
For max. 2 specimens, which do not fulfill the requirements, 2
replacement specimens each from the same part can be tested.
No value should lie below the required minimum value.
6.2.3 Manual test
This version of the technological bending test is a simple
indicative workshop test. Because of the force required this
method is limited to small thickness specimens.
The specimen is bent with the machined side of the weld over a
rounded, 6 mm thick bar with powerful application of force as per
3) (R) Messrs Hoechst AG. Extensive testing experience is available for this test medium, which facilitates comparison of the results and the determination
of requirements. If other products on the same basis are used, compare the number of ethylene oxide molecules in the polyglycol ether chain.
Page 7 to DVS 2207-5
Fig. 8 until fracture or until the free ends of the specimen come
into contact with the bar.
Figure 8. Diagrammatic representation of the manual test.
6.3 Manual peel test
The manual peel test is a simple, indicative workshop test carried
out by hand, which can also be carried out on site. This test is
intended in particular for lap welded joints, for example
electrofusion-welds, which cannot be directly tested using the
technological bending test as per Section 6.2.
6.3.1 Execution
The execution can only take place after adequate cooling of the
joint to room temperature (approx. + 23 °C). 5 strip specimens of
15 to 20 mm width – taken at intervals over the weld length – are
tested.
Here the end of the sleeve is clamped in the vice and the non-
welded end of the plastic casing pipe projecting into the sleeve is
bent away from the sleeve until it can be gripped by a pair of
pliers. Then an attempt is made to peel off the joint, see Fig.9.
The free leg is bent until it kinks.
Sleeve
a) Plastic jacket pipe b)
Figure 9. Illustration of the specimens for the manual peel test;
a) strip specimen before the test
b) joint ends bent upwards for the peel test.
6.3.2 Evaluation
The joining surfaces should not separate.
6.4 Tensile creep test
The long-term behaviour under the required forms of stress is the
most important proof of quality in relation to the suitability for use
of load carrying components made of thermoplastic polymers. In
the case of pressure loaded structures, such as pipes and
fittings, carrying out the long-term internal pressure test has been
the proven state of the art for a long time. For pipes of larger
dimensions, however, these tests are increasingly expensive in
cost terms, so that this test is only seldom used in testing
practice.
To assess the execution of the weld the long-term tensile test in
combination with other tests has proved itself. The tests are
carried out at + 80 °C. The applied stresses are 4 and 3 N/mm2.
If no brittle fracture should occur during the execution of the test,
lower stresses must be chosen. In order to shorten the time-to-
failure (acceleration effect), a 2% aqueous wetting solution (for
example Arkopal N 100 3) ) should be used as the test medium.
375
Page 8 to DVS 2207-5
The required joining factors (fs) in the tensile creep test (Table 4,
Section 7) and the fracture photomicrograph give an indication of
the quality of the weld execution.
R&D INTAKE MANIFOLDS
6.4.1 Execution
The tensile creep test is carried out in accordance with DVS 2203
Part 4 or DIN 53 444 (Fig.10). The welded joints are tested in
accordance with the actual execution.
dial gauge
specimen
test medium
tank test weight
Figure 10. Test set-up for the tensile creep test (on the basis of DVS
2203 Part 4).
For the shapes and dimensions of the specimens the specimen
shapes (Fig.6) indicated in Section 6.1 "Tensile Test" with Table
1 are applicable. For this test the use of the same specimens is
recommended. The joint position lies in the middle of the
specimen, the longitudinal axis of which must lie in the direction
of the tensile force.
The specimen must be made without notches and if necessary
retouched after visual examination (for example grinding in the
longitudinal direction). In the tensile creep test the duration until
fracture of the specimen and, if necessary, the increase in
elongation with time are determined.
The specimens are stressed at constant temperature (± 1°C) with
uniformly steady tensile force (± 1%) and constant ambient
conditions.
In order to ensure even concentration of the wetting agent, it
must be circulated continuously in the test bath. The bath
concentration of the test medium must be monitored by control
measurements – in its spatial distribution also – (for example by
residue determination by evaporation). Evaporated water must
be topped up by adding demineralized water (deionate)
continuously (level control).
After reaching the bath temperature the specimens are
vigourously stressed with the test force but without impact in the
test bath, the force being maintained constant during the test.
The duration of loading is calculated from the moment the test
force is reached and recorded by built-in dial gauges.
In order to determine the gradient of the creep curve (straight
lines in double logarithmic form), the tests are carried out under
at least 2 stresses (for example 4 and 3 N/mm2). At least 6
welded and 6 unwelded specimens are tested for each stress.
The mean value is calculated as the geometric mean of the
individual values.
4) On the basis of the shape and nature of the lap welded joints involved here with superimposed types of stress in the joints in the tensile test, the long-
term joining factor is defined here, as a departure from DVS 2203 Part 4.
376
6.4.2 Evaluation
For determining the long-term joining factor4) (fs) the creep curve
of the welded and unwelded specimens must be determined, the
gradient of the straight lines being particularly important. The
tensile creep joining factor – referred to a particular stress on the
reference curve B – is calculated from the curve obtained for the
welded specimen: see examples in Fig.11.
Alternatively, the ong-term joining factor can be referred to one
test stress on the reference specimen. The joining factor
determined must then be identified, with indication of this test
stress (for example σ4(B)), see Fig.12.
Simplified method for minimum proof of a required long-term
joining factor
To reduce the complexity of the test the proof can be limited to
one stress level in each case using the following method, see
Fig.13.
For example:
– Test stress for the basic material (reference specimens)
σB = 4 N/mm2
– Test stress for the weld specimens with for example fs = 0.8
σS = fs ∙ σB = 0.8 ∙ 4 N/mm2 = 3.2 N/mm2.
If the weld specimens reach at least the same mean time-to-
failure as the base material, at least the required long-term
joining factor is demonstrated (yes/no statement).
With this test no conclusion about the stress-related strength
behaviour is possible.
6.5 Imperviousness test
Normally a positive pressure test with compressed air at approx
0.2 to 0.3 bar is carried out. After a test duration of at least 10
minutes after coating the welds with a harmless foaming aqueous
solution (for example a modern biologically degradable
household detergent in the lowest concentration) no leaks must
be visible (bubble formation).
7 Requirements imposed on welded joints
The welded joints on PE-HD casing pipes and fittings must – just
like the tubes – reliably withstand the stresses occurring in
operation over the design duration of stress.
As a rule welded joints on PE-tubes do not achieve the same
material strength as the unwelded casing pipe. The piping
planning and design must indicate the weld qualities achievable
with the welding methods used. The required weld qualities must
be guaranteed by suitable measures and test methods.
Therefore corresponding requirements must be imposed on the
welded joints.
In the Directive DVS 2203 Part 1 requirements imposed on
plastic welded joints are described for certain moulding
compounds and welding methods, as are applied mainly in tank,
vessel and piping construction. In these fields of application the
plane butt joint without transition is used and welded.
In the case of lines with PE-casing pipes the multiple lap joint is
also often used in special process variants, however from a test
point of view and also in respect of the requirements imposed it
cannot be immediately treated and assessed. Otherwise the
requirements of the Directive quoted apply.
7.1 Visual test
In the visual test the defect-free execution of the welded joint
must be demonstrated by visual examination. In combination with
destructive tests the weld cross-section and fracture surfaces
must also be assessed. Typical test features are:
 Page 9 to DVS 2207-5

– a process-specific, correct weld/weld edge formation (root and – homogeneity of the material being welded; weld surface
edge welding) – weld flash, weld shoe guidance (WE)
– presence of notches, cavities, lack of fusion, etc – bulge/double bulge formation (HS, WZ)
– the effect of heat, fusion zones, overheating, etc

R&D INTAKE MANIFOLDS

Defect descriptions and evaluation references are also given in
– shape and uniformity of the weld formation DIN 32 502 and DVS 2202 Part 1.
Stress (N/mm2)

S = weld specimen
B = reference specimen

Time-to-failure (h)

Figure 11. Diagramatic representation for defining the joining factor in the tensile creep test.
Stress (N/mm2)

S = weld specimen; σ4 and σ3

B = reference specimen; σ4

Time-to-failure (h)

Figure 12. Diagram for defining the joining factor in the tensile creep test in the case of only one test stress on the refrence specimen.

7.2 Mechanical-technological tests in the short-term test
In principle, in the short-term tests described (tensile and
technological bending tests) the requirements of DVS 2203 Part
1 must be satisfied; see Table 3 and Fig.14.
In the case of lap welded joints with flat welding in the joint the
result of the tensile stress is primarily determined by the weld
edge execution; the welding itself is covered to a lesser extent in
this tensile/shear test. During the manual peel test to Section 6.3
proposed as an alternative for these joint shapes the surfaces to
be joined must not separate.
With this form of joint the technological bending test cannot be
carried out easily. Likewise, essentially only the weld edge
regions are covered by the test.
The results of these tests have less informative value for lap
welded joints, in particular for flat welds in the lap joint, than for
plane butt joints.

377
Page 10 to DVS 2207-5

Stress (N/mm2)
R&D INTAKE MANIFOLDS

S = weld specimen
B = reference specimen

Time-to-failure (h)

Figure 13. Simplified method for minimum proof of a required long-term joining factor.

Table 4. Requirements for the joining factor in the tensile creep test
for the reference stress σ = 4 N/mm2 (on the basis of DVS
2203 Part 1).

Welding method Tensile creep

joining factor fs
Heated plate welding 0.8
V-weld extrusion welding 0.6
Extrusion welding on the lap joint with fillet
weld 0.5*)
Electrofusion in the lap joint 0.5*)
Bending angle

*) At present values from approximately fs = 0.4 are accepted. This low

value is permitted in order to take into account the falsification of the
tensile test due to the superimposed bending stresses, increased
inherent stresses and notch effects, etc.

7.3 Tensile creep test

In the tests as per Section 6.4, for correctly executed joints on

casing pipes at least the long-term joining factors "fs" required in
Table 4 must be demonstrated.
For the tubular semi-finished products (casing pipe and tubular
sleeves), under the same test conditions as in Section 6.4 for the
test stress 4.0 N/mm2, a minimum time-to-failure of 1500 hours is
required for the geometric mean value from at least 6 individual
specimen results, see Draft Standard DIN EN 253.
Specimen thickness
This single-point requirement in the creep diagram (+ 80 °C)
HS = Heated plate welding applies subject to the condition that the tube moulding material
LE = Light beam welding by extrusion of filler material basically satisfies at least the creep requirements in the internal
WE = Hot gas welding by extrusion of filler material pressure test according to the creep diagram used as the basis
WF = Hot gas welding with torch separate from filler rod
WZ = Hot gas string-bead welding for DIN 8075.

Figure 14. Requirements for the technological bending test (from DVS In accordance with the current quality standard, here the inclined
2203 Part 1). load range of the curves is shifted in such a way along the time
axis that the test point (4.0 N/mm2 /+ 80 °C) lies at 1000 hours.
Table 3. Joining factor requirements in the shoert-term tensile test In comparative tests it has been shown that in the case of the lap
(on the basis of DVS 2203 Part 1).
welded joints the deformations in the test specimens (strips or
Welding method Short-term tensile shoulder specimens) have no influence on the test result (pairs of
joining factor fz forces).
Heated plate welding 0.9
V-weld extrusion welding 0.8
7.4 Imperviousness test
Extrusion welding on the lap joint with fillet
weld 0.8 During the imperviousness test (as per 6.5) no leaks, atypical
Electrofusion in the lap joint 0.8 deformations or other impermissible changes may occur.

378

8 Quality Assurance
Because the quality of plastic welded joints for specific
applications can in the last analysis only be demonstrated by
R&D INTAKE MANIFOLDS
destructive long term tests, the quality assurance must be based
on indices, identity and reproducibility proofs.
Therefore, for the quality assurance of welding work in the case
of joints in PE-HD casing pipe and fittings, in addition to the use
of moulding compounds and tube products with fixed indications
of product qualities, qualification requirements must be imposed
on the skilled welding personnel and minimum requirements on
the equipment and workplace arrangements of the contracting
companies.
8.1 Quality assurance for casing pipes and fittings in the
manufacturer's works
The measures for quality assurance in the manufacturer's works
are normally divided into two. According to DIN 18 200, a
distinction is made between internal and outside supervision:
– Internal supervision
Tests by professionals of the manufacturer's works based on
established test and work instructions.
– Outside supervision
These are used to permit the regular checking of the equip-
ment and operations of the internal works inspectors, their do-
cumentation and test procedures by outside supervisors. For
the application described here, as a rule the outside supervi-
sion is carried out and administered by suitable independent
plastics test centres and experts as per DIN 18 200. As a rule
outside supervision dates are observed and certified twice per
year. The results of the supervision inspections must be docu-
mented and the test reports of the outside inspector included in
the manufacturer's documentation.
8.2 Proof of quality for casing pipes and fittings
For the casing pipes and fittings used tests must be carried out in
accordance with the basic standards, moulding compound and
moulding guidelines already in existence for the products or
according to a product-specific test and supervision program.
The test results obtained must be specified and documented,
contrasted with the established requirements.
The content of the test must be based on:
– DIN EN 253, 448, 488 and 489 for PE-HD casing pipe materi-
als
– DIN 8074/75 applied rationally, in particular in respect of the
long-term tests. In the case of the larger tube diameters with
smaller wall thicknesses tensile creep tests are preferable to
the otherwise customary long-term internal pressure tests in
this respect. For the minimum time-to-time failure rates the
requirements under Section 7.3 apply.
The proofs of quality must be produced by the manufacturing
works at least in the form of "Works Certificates" as per 2.2, DIN
50049. For the content of the tests and the application of internal
or outside supervision, see Annex 5.
8.3 Quality assurance of the welding work
Process tests must be demonstrated by the contracting
companies and skilled workers for the welding method applied
(proof by the manufacturing company that it is in a position, with
its skilled personnel and the physical equipment of the company,
to execute the welding work correctly and reproducibly in
accordance with the high requirements imposed.
5) Training centres for PE welders:
– Süddeutsches Kunststoff-Zentrum, Frankfurter Straße 15-17, D-97082 Würzburg
– Training centres under supervision of the Institut für Kunststoffverarbeitung at Aachen
University of Technology, Pontstraße 49, D-52056 Aachen
6) Examination centres:
- the Training Centres mentioned under 5) and
- the TÜV Plastic Test Centres; for information: Association of the Technical Supervision Societies, Kurfürstenstrasse 56, D-45038 Essen.
Page 11 to DVS 2207-5
The welders used must demonstrate adequate training5) in the
material science of PE- HD, having passed the welder
examination6). These must be carried out and certified as per
Directive DVS 2212 or in rational application for the particular
method. For the methods WZ and HS DVS 2212 Part 1 and Part
2 apply to extrusion welding.
The execution of the welding work in the manufacturer's works
(prefabrication of fittings) and – in particular – on the site under
difficult conditions in pipe trenches, must be supervised by a
qualified responsible welding inspector of the manufacturer's
works.
The welding inspector must supervise in particular
– The use of suitable welding equipment and accessories in a
functionally reliable condition,
– The correct arrangement and preparation of the joints
– The qualified execution of the welding processes in accor-
dance with the particular prescribed methods (Manufacturer's
instructions, DVS Directives, etc.) if necessary using suitable
protective measures (protection against weather, etc),
– Adequate recording of the welds (for suggested report forms
see Annex) with welder identification and documentation of the
joints in accordance with what is stated in the manufacturer's
specifications and DVS Directives relating to the method.
Finally, he carries out
– The visual examination of the finished welded joints for defect-
free execution and
– The imperviousness test
and prepares a test report on these.
The welding inspector is responsible to and reports to the
Employer/the Site Management.
For the execution of the welding work done by the Employer,
outside supervision is recommended on a random basis.
9 Standards, Directives
9.1 Standards
DIN EN 253 Preinsulated bonded pipe systems for underground
(Draft) hot water networks – Pipe assembly of steel
service pipes, polyurethane thermal insulation and
outer casing of high density polyethylene.
DIN EN 448 Preinsulated bonded pipe systems for underground
(Draft) hot water networks – Fitting assemblies of steel
service pipes, polyurethane thermal insulation and
outer casing of high density polyethylene.
DIN EN 488 Preinsulated bonded pipe systems for underground
(Draft) hot water networks – Steel valve assembly of steel
service pipes, polyurethane thermal insulation and
outer casing of high density polyethylene.
DIN EN 489 Preinsulated bonded pipe systems for underground
(Draft) hot water networks – Joint assembly steel service
pipes, polyurethane thermal insulation and outer
casing of high density polyethylene.
DIN 1910 Welding, Welding of plastics, methods
Part 3
DIN 8074 Tubes of high density polyethylene (PE-HD),
dimensions
DIN 8075 Tubes of high density polyethylene (PE-HD),
general quality requirements, testing
379
Page 12 to DVS 2207-5

DIN 16 776 Polyethylene (PE) moulding compounds DVS 2205 Design of containers ans appaartus made from
Part 1 – Classification and description thermoplastics
Part 2 – Manufacturing the test specimens and Part 1 Characteristic values
determining the properties Part 3 Welded joints
DIN 16 963
Part 5 R&D INTAKE MANIFOLDS
Pipe connections and piping components for high
pressure pipelines of high density polyethylene
(PE-HD); general quality requirements, testing
DVS 2206 Testing of components and constructions made of
thermoplastic materials
DVS 2207 Welding of thermoplastics, PE-HD (high density
DIN 18 200 Supervision (quality monitoring) of building Part 1 polyethylene) Pipes and pipeline components for
materials, components and structures, general gas and water mains
principles Part 2 Heated plate welding – pipes and pipelines for
DIN 32 502 Effects on welded joints in plastics, classification, sewerage pipes and lines
designation, explanations Part 3 with Annex Hot gas welding of thermoplastics –
DIN 50 049 Certificates for material tests sheets and pipes, welding parameters)
DIN 53 444 Testing of plastics, tensile creep test Part 4 Welding of thermoplastic polymers, panels and
DIN 53 455 Testing of plastics, tensile test pipes – extrusion welding
DIN 53 479 Testing of plastics and elastomers; determining the DVS 2208 Machines and equipment for welding of
density thermoplastics
DIN 53 735 Testing of plastics; determining the melt flow index Part 1 – heated tool welding
of thermal plastics Part 2 – hot-gas welding (not extrusion welding)
ISO Plastics; determination of the melt flow index (MFR) DVS 2209 Welding of thermoplastics – extrusion welding,
1133:1991 and the volume flow index (MVR) of thermal Part 1 methods – features
plastics DVS 2211 Filler materials of thermoplatics, scope,
ISO Plastic pipes for conveying liquids; determination of designation, requirements, tests
1167:1973 the resistance to internal pressure DVS 2212 Testing of welders for welding plastics,
ISO Plastics; methods for determining the density and Part 1 Test group I (hot gas string bead welding and
1183:1987 relative density of non-expanded plastics heated plate welding)
ISO/DIS Tubes of polyethylene (PE); Part 1: Determination Part 2 Test group II; Hot gas extrusion welding (WE)
6259-1:1985 of the properties in the tensile test
GKR- Casing pipes for the manufacture of sleeves and
ISO/TR Determination of the thermal stability of Guideline fittings of PE-HD (high density polyethylene) for
10 837:1991 polyethylene (PE) for gas piping and fittings R 9.3.17 preinsulated bonded pipe systems for underground
hot water networks with the quality symbol of the
9.2 Directives Plastic Pipes Quality Association e.V., Bonn
DVS 2201 Testing of semifinished products of thermoplastics "Building of district heating networks" – Technical Guidelines of
Part 1 – fundamentals, references the AGFW
DVS 2202 Imperfections in thermoplastic welded joints – AGFW membbers information "Plastic jacket pipes for district
Part 1 features, description, evaluation heating lines".
DVS 2203 Testing of welded joints og thermoplastics
Part 1 Test methods – requirements
Part 2 Tensile test
Part 4 Tensile creep test
Part 5 Technological bending test

380
 Assembly Report

Order No.: Welder:

BV/Section: Welding machine No.:

Section No.: of: Power source: Mains Generator

Sleeve No. Type Section Date Ambient Weather Weather Displays Sleeve Remarks
temperature protection
(°C)
A B C

Tent

Sunny
Wind
Time
Temperature

Sleeve initial temperature (oC)

Snow
Open
Rewelds

Screen
Replacement welds
Watertight

Programme

Cloudy
Non-watertight

Rain
Annex 1: Report form (proposal) for the electrofusion method
This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

Page 13 to DVS 2207-5

381
382
Report form for heated plate welding of tubular Laid above ground Material
Laid underground Sheet of
components
Employer Contracting company Welding machine Weather conditions Protective measures

Make: 1 = sunny 1 = none

Page 14 to DVS 2207-5

2 = dry 2 = screen
Order title Name of the welder Identy No. Type: 3 = rain or snowfall 3 = tent
4 = wind 4 = hetating
Maschine No.:

Order No. Name and company of the welding Year of manufacture: In the case of multiple designations follow the sequence of the figures as above
inspector (e. g. 34 = rain and wind)

Weld Date Input data Adjustment/measurement values1): theoretical/acutal information Ambient conditions Remarks
No.
Pipe size Movement Heating Equalizing Heating up Joining Heating Adaption Time to Cooling Ambient Weathe- Code No.
Ø dA × t pressure, element temperature up time2) time2) complete time under temperature ring of the
measured, temperature’ joining joining code No. protective
P pressure pressure2) measures
bar oC bar bar bar s s s s oC
Annex 2: Report form (proposal) for heated plate welding
This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

Example: (10,5+10,7) (10,5+0,7) (10,5+10,7)

1 25.5.92 160Ø14,6 10,5 220 ± 5 21,2/ 11,2/ 21,2/ 130/ <10/8 ≈ 10/12 >20/20 ≈ 20 24 2 None

Signature of welder: Date and signature of the welding inspector:

1 )The settings are the sum of the movement pressure and the indications of the manufacturer of the welding machine concerning equalization and joining pressure.
2) The measured values must be entered.
 Page 15 to DVS 2207-5

Annex 3: Report form (proposal) for extrusion welding

This Annex is only for information and is not a binding part of this Directive.

Welding Report
R&D INTAKE MANIFOLDS
for the extrusion welding of panels and tubes

General Information

Order No.: Drawing No.:

Contracting Company:

Welder (Name, Reference):

Process/Equipment

Process variants: Welding shoe No.:

Welding equipment (make):

Weld shape (e. g. DVS 2205):

Material

Material to be welded:

Semi-finished product shape, thickness (mm):

Welding filler:

Welding Conditions

Hot air temperature (°C): Air volume (l/min):

Cylinder heating (°C): Compound temperature (°C):

Hose heating: Welding speed (mm/min):

Remarks:

Date/signature Date/signature
Welder Welding supervisor

383
Page 16 to DVS 2207-5

Annex 4: Report form (proposal) for imperviousness test

This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

Imperviousness Test
Acceptance Order No.

Project:

Building section/line section No.:

Sleeve No. Positive pressure Welder Tested and accepted Date

VL RL 0.2 bar Name Signature

Remarks:

384
 Page 17 to DVS 2207-5

Annex 5: Content of test and organization of internal and outside supervision

This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

This Annex to the Directive contains the content of the test for the
Quality Assurance of PE casing pipe and tubular sleeves and
corresponding sleeve plates, Table A5-1. The content of the test
– DIN 8075 (05/87)
– DIN 16 963 Part 5 (10/89)
for the Quality Assurance of welded joints in fittings and sleeve – GKR Guideline R 9.3.17 (05/92)
joints (welding in the works and on site) is also specified; Table
A5-2. It isbased on the requirements of the official product In Tables A5-1 and A5-2 recommendations for a Quality
standards and guidelines: Assurance Certificate are given. In the list of obligations of the
– DIN EN 253 (4th draft revision; issued on 1.11.1991 in the TC contractual partners special stipulations can be imposed
107) concerning the tests to be carried out, the scope and frequency.
– DIN EN 448 (pr EN; issued on 1.11.1991 in the TC 107)

385
386
Table A5-1. Monitoring tests on semi-finished products (casing pipes and tubular sleeves and sleeve plates); FM = moulding compound, HZ = semi-finished product.

Serial Application Tests Execution as per Requirements as per/ Test/frequency

Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
Page 18 to DVS 2207-5

1 – Technological tests
1.1 5.2.1 – Density of the tube material × DIN 53 479 DIN EN 253, Section 4.2.1.1
E.g. Method A GKR Guideline R 9.3.17
ISO 1183:1987 "A" or "D" > 0.944 g/cm3
1.2 5.2.1 – Melt index, × × DIN 653 735 DVS 2207-5, Section 3
"MFI 190/5" (g/10 minutes) ISO 1133:1981 DIN EN 253, Section 4.2.1.2
GKR Guideline R 9.3.17
Execution of the
For moulding compounds: Execution of the In general twice
tests described
tests described per year1)
a) 0.4. ... 1.3 on each delivery
a) (classes 005 and 010
a) DIN 16 776 T1)
For welded joints:
a) ∆MFI ≤ 0.5
b) MFI(HZ) ≤ MFI (FM) + 0.22)
1.3 4.2.1.3 – Oxidation stability (OIT) × (×) ISO/TR 10 837 DIN EN 253, Section 4.2.1.3 Manufacturer's
GKR Guideline R 9.3.17 certificate per
200°C/> 20 minutes batch

1.4 – if necessary dry loss × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17
> 0.1 % Execution of the
Execution of the In general twice
tests described
1.5 – if necessary homogeneity × × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17 tests described per year1)
on each delivery
Non-homogeneities < 0.02 mm2
R&D INTAKE MANIFOLDS
 Table A5-1. Continuation.

Serial Application Tests Execution as per Requirements as per/ Test/frequency

Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
2 Condition and dimensions
2.1 5.2.3 – Surface condition × DIN 8075 DIN 8075
DIN EN 253 DIN EN 253, Section 4.2.2.4
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Unacceptable features Continuous
inspection during
2.2 5.2.2 – Dimensional stability × DIN EN 253 DIN EN 253, Section 4.2.2.3 production
GKR-Guideline R 9.3.17 Execution of the In general twice
tests described per year1)
see permissible limits of
deviation
2.3 5.2.4 – Hot storage × DIN EN 253 DIN EN 253, Section 4.2.2.6 Once per week
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Deformation ≤ 3%
3 Mechanical tests
3.1 4.2.2.5 – Elongation at tear in the × DVS 2203-2 DIN EN 253, Section 4.2.2.5 Once per week Generally twice
tensile test ISO/DIS 6259, Section 1.2 GKR Guideline R 9.3.17 per year1)
DIN 53 455
≤ 350%
Test speed = 100 mm/min
3.2 5.2.5 – Long-term internal ×3) (×) DIN 8075 DIN EN 253, Section 4.2.1.4 Once per week, Generally twice
pressure test ISO 1167 if stipulated in per year, if
Execution of the
detail stipulated in
tests described
detail1)
3.3 5.2.6 6.4 Tensile creep test in the × × DVS 2203-4 DIN EN 253, Section 4.2.2.7 Four times per Generally twice
wetting agent bath (ISO/DIS 6259 Section GKR-Guideline R 9.3.17 year per year1)
1.2)
> 1500 h in the water bath with
2% wetting agent at 80°C;
= 4.0 N/mm2

Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
2)
R&D INTAKE MANIFOLDS

HZ = result on the semi-finished product. FM = result on the moulding compound (pellets)

3) As type test on the extruded specimen tube and as alternative to the tensile creep test in product supervision.
x Execution of the test described.
(X) Execution, if stipulated in detail
a Per machine, dimension, type of compound, or per per production run
b At least per type of compound, machine and group diameter once per year.
Page 19 to DVS 2207-5

387
388
Table A5-2. Monitoring tests on welded joints (works and site welds)

Consecutive Application standard, Type of tests Execution as per Requirements Test/frequency

item No. Section in: as per
Process Workshop welds Site welds
DIN EN DVS 2207-5 tests welding outside welding outside
253 (448) supervisor supervision supervisor supervision
Page 20 to DVS 2207-5

1 – 7.1 Visual examination Visual inspection DVS 2207-5, 100% 100%

Section 7.1
2 – 6.1 Short-term tensile test DVS 2203-2 DVS 2207-5,
DN 53 455 Section 7.2 As part of the As part of the
3 – 6.2 Technological bending DIN 2203-5 DVS 2207-5, welder and welder and
test DIN 2207-5, Section 6.2.1 Section 7.2 Execution work work
In general In general
of the examinationsb) examinationsb)
4 – 6.3 anual peel test DIN 2207-5, Section 6.3.1 DVS 2207-5, twice per twice per
tests
(alternative to Item 3) Section 6.3.2 year1) year1)
described
5 – 6.4 Tensile creep test in DVS 2203-4 DVS 2207-5, Four times per
wetting agent bath DVS 2207-5, Section 6.4 Section 7.3 yeara)
DIN 53 444
6 – 6.5 Imperviousness test DVS 2207-5, Section 6.5 DVS 2207-5, 10 ... 20% 100%
Section 7.4

Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
a) At least for each compound type, machine and diameter group once per year
b) Per method, type of material and welding machine
Welder examinations based on DVS 2212
Project-related work tests at the beginning of work; at least half yearly
R&D INTAKE MANIFOLDS
 Page 21 to DVS 2207-5

Annex 6: Determination of the time factor and a fictitious joining factor for a welded joint
This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

If creep tests are only carried out under one test stress (for 2. The slope of the curve of the single-axis tensile creep test cor-
example where σ = 4.0 N/mm2), from the results for the base responds in its slope to the curves of the multi-axis long-term
material and the welding specimens only the ratio of the internal pressure tests to DIN 8075; shift of position only on
evaluated times-to-failure (geometrical mean value "XG") can be the time axis.
formed and as the time factor
3. The slope of the curves of welded specimens corresponds to
x G(S) the slope of the base material specimens (parallel trend). Ex-
f s(t) = ------------- perience has shown that this is only applicable to high quality
x G(B)
butt joints!
be specified.
In the example in Fig.A6-1 the fictitious joining factor is
This time factor is not identical with the joint factor (fs) calculated
from the significance ratio of the stresses. =
f′ s ( σ ) =
2,0/4,0 0,5
If nevertheless – in the absence of basic curves for the tube
material from tensile creep tests – a comparison factor is formed The time factor from the results of the tensile creep test works out
by including known long-term internal pressure curves (for at
example the minimum value curves from DIN 8075) for PE-HD
tubes, this is based on the following assumed conditions: =
fs ( t ) =
67/1500 0,045
1. The long-term internal pressure curves of the casing pipes
correspond in their slope to the minimum curves of DIN 8075. This fictitious joining factor cannot be used as a calculation value.
Comparative stress in N/mm2 is the long-term internal pressure test

Applied stress
in the tests R
ef
As

e
su

re
nc
m
pt

e
io

sp
n:

ec
w

i m
el

en
di
ng

Z-
S-
sp

Z-
ec

V
im

(8
en

0o
cu

)
rv
e

Time-to-failure in years

Time-to-failure in hours
Figure A6-1. Formation of a fictitious joining factor f′s(σ ) from test results of the tensile creep test (Z-S-Z-V) for only one test stress; for example
σ = 4.0 N/mm2.

389
Page 22 to DVS 2207-5

Annex 7: Stressing of welding sleeves in plastic jacket pipes

This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS

Like the PE-casing pipes, the welding sleeves are exposed to
mechanical loads. The stresses are caused by
– friction in the subsoil
– possible drag of the sleeve and
– restricted elongation due to temperature.
Because the level of the mechanical stresses has a critical
influence on the working life of the joint, the stresses occurring
are estimated for 3 different cases of loading. The significant
loads are in each case the stresses in the axial direction.
Estimates: – sheath friction σR = µ ∙ p
– drag σSt
– restricted elongation due
– to temperature σT = αT ∆T E
Calculation assumptions: DN 250, Da = 400mm, t = 6 mm
Case 1: Fitted welding sleeve without drag,
hü = 60 cm in the expansion buffer, µ = 0.25
Case 2: Welding sleeve with high drag,
hü = 60 cm in the sand bed, µ = 0.5
Case 3: High drag, parking heavy truck with 60 t
(called: SLW 60),
hü = 1.5 m in the sand bed, µ = 0.5.
The results of the guide calculations should be taken from Table
A7-1.
The calculations have been carried out taking into account the
relaxation with temperature, using values of E (σ = 0.75 N/mm2
and 1 N/mm²).
The following conclusions should be drawn:
– With the usual plastic jacket pipes applications axial stresses
of max 2 N/mm2 are to be expected in the sleeve wall.
– In extreme cases stresses of up to 4.5 N/mm2 are also possi-
ble.
– The effect of the drag on the axial stress is small.
-– In the case of the traffic loads, the "parking SLW 60" load re-
presents the most unfavourable stress. Because of the disper-
sion of the load coming from the wheel loads with depth, this
load represents the critical load for the sleeve joint when there
is little cover above it. The probability that an SLW 60 will park
over a sleeve is however very remote, because the axle load of
an SLW 60 is twice the maximum possible according to the
Road Traffic Authorization Order.
– Expansion pads reduce both the sheath friction and the drag
loads and increase the stress due to restricted thermal expan-
sion. In all, however, the stress-relieving effect predominates.
This occurs in particular with high mechanical stress (for ex-
ample depth of cover or traffic loads).
This information is at present under discussion in the specialist
circles. The calculations based on other hypotheses and
assumptions lead to different results, but are of the same order of
magnitude.

Table A7-1. Axial stresses in the sleeve wall.

σR σST σT σres
[N/mm2] [N/mm2] [N/mm2] [N/mm2]
Case 1 µ = 0.25 0.3 0 approx 1 1.3
σ = 1 N/mm2
T = + 25 oC
E = 120 N/mm2
Case 2 µ = 0.5 0.6 0.2 approx 0.8 1.6
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2
Case 3 µ = 0.5 2.7 0.7 approx 0.8 4.2
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2

390
 Erstellungsdatum: 12.02.2002
Letzte Änderung: 18.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-05\BEIBL1\e2207-5b1.fm

DVS – DEUTSCHER VERBAND Welding of Thermoplastics Directive D

Welding of PE Casing Pipes DVS 2207-5
FÜR SCHWEISSEN UND
Supplement 1 V
VERWANDTE VERFAHREN E.V. – Fittings and Isolating Valves – (July 1997) S 
R&D INTAKE MANIFOLDS
Content: 2 Material and semi-finished products

1 Scope PE-HD in accordance with paragraph 4.2 of DIN EN 253 must be

2 Material and semi-finished products used as a material for fittings to be made by welded joints.
3 Carrying out the welding process
3.1 Preparation and requirements for carrying out the process In order to ensure suitability for welding, the mass flow rate of the
3.1.1 Inspection of the condition of the heating tools and air materials to be welded must satisfy the requirements of DIN
supply EN 253, paragraph 4.2.1.2. This means that the mass flow rate
3.1.2 Operating test of the equipment and machines used (MFR 190/5) of the materials to be welded may not differ by more
3.1.3 Work and workplace than 0.5 g/10 minutes.
3.2 Heated plate welding (HS)
3.2.1 Equipment requirements PE-HD in accordance with DIN 8075 must be used as welding
3.2.2 Preparation of the welded material / joint sub-faces filler under paragraph 7.3 of DVS 2207-5, with state of the art
strength properties in respect of its creep behaviour, depending
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

3.2.3 Welding process

3.3 Hot gas extrusion welding (WE) upon the welding method used.
3.3.1 Equipment requirements Only qualifying tubes with appropriate, informative test
3.3.2 Preparation of the welded material / joint sub-faces certificates under or on the basis of DIN EN 253, or moulding
3.3.3 Welding process materials in accordance with DVS 2207-5, may be used as semi-
3.4 Hot gas string bead welding (WZ) finished products.
4. Testing welded joints
4.1 Non-destructive testing methods – visual inspection
4.2 Destructive testing methods
3 Carrying out the welding process
4.2.1 Tensile test
4.2.2 Technological bend test
4.2.3 Tensile creep test The following welding processes are used for producing PE
4.3 Imperviousness test casing pipe fittings:
5 Requirements on the welded joints In the factory:
5.1 Visual inspection
5.1.1 Indications of good HS welded joints – Heated plate welding (HS) for segmental construction or in
5.1.2 Indications of good WE welded joints conjunction with “outward necked” pipes;
5.1.3 Indications of good WZ welded joints
5.2 Requirements for the tensile test – Continuous and intermittent hot gas extrusion welding (WE)
5.3 Requirements for the technological bend test (DVS 2209-1), possibly with a root pass produced by hot-gas
5.4 Requirements for the tensile creep test string-bead welding (WZ), if necessary.
5.5 Requirements for the imperviousness test
If production on site is necessary, e.g. for modifications, repairs,
6 Quality assurance
etc:
7 Standards and directives
– Hot gas extrusion welding and

1 Scope – Under exceptional circumstances – restricted access, etc –

This Supplement to Directive DVS 2207-5 applies to all PE-HD
factory and site casing pipe welded joints on segmental bonded
prefabricated fittings (elbows, T-pieces, adapters and anchor
points) in accordance with DIN EN 448 and underground
isolating valves within the scope of plastic casing pipe systems
for district heating networks in accordance with DIN EN 488.
The HS (heated plate) welding method must be used for factory
casing pipe joints and the WE (hot gas extrusion) method in
exceptional and special cases.
Site casing pipe joints must be made using the WE method and
the WZ (hot gas string-bead) method in exceptional and special
cases.
hot gas string-bead welding.
In addition to the process stipulations, characteristics and
requirements in Directive DVS 2207-5 for welding PE casing
pipes, predominantly in site production, the following stipulations
must be observed in the production of fittings.
Only suitable, calibrated and regularly-maintained machines and
equipment may be used to execute welds. The appropriate
working instructions – process and parameter stipulations – must
be available at the workplace: see also DVS 2208-1 and DVS
2209-2.
Welds must only be made by qualified welders certificated for the
process under Directive DVS 2212.

This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.

A working out of the common DVS-/AGFW-working group “Schweißen von PE-Mantelrohren”

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150

391
Page 2 to DVS 2207-5 Supplement 1

3.1 Preparation and requirements for carrying out the process – A user-friendly adjustment facility for aligning the work at the
Equipment operation tests and parameter checks must be welding point (to minimise face offset).
carried out before work commences, and the following conditions
guaranteed. Table 1. Permissible gap widths and deviations from plane-paralle-

R&D INTAKE MANIFOLDS

3.1.1 Inspection of the condition of the heating tools and air supply
The proper condition of the heating tools and energy media must
be verified at appropriate intervals before and during the work.
– Superficial condition (PTFE coating) of the heated plates;
lism of the clamped, machined pipe faces
(a) By bending and beaming up the equipment guides and
jigs1)
(b) Deviations from the plane-parallelism of the machined
faces when clamped with minimal contact pressure
between the ends of the pipes pushed together.

– Heat regulation, temperature maintenance, maintenance of Permissible gap width Nominal external casing pipe diameter
settings;
[mm] [mm]
– Water- and oil-free air supply for extrusion and hot gas
processes; maintenance units for stationary compressed air ≤ 0.5 ≤ 355
supply;
≤ 1.0 400 ≤ 560
– Correct allocation and dimensions of hot gas jets (WZ and WE)
and welding tools (welding shoes for WE) for the types of weld ≤ 1.3 630 ≤ 800
to be completed. ≤ 1.5 > 800
3.1.2 Operating test of the equipment and machines used
– Sufficient heated plate output and an even heat flux – also in
The operational safety of the machines and equipment used the case of split heated plates – into the welding zones; no
must be tested: residual parting marks in the weld and bead;
– Target/actual comparison of the parameters set for sufficient – Permissible overall temperature deviation of both the opposing
working time/preheating time with suitable measuring points of the heated plate and across the entire area of the
equipment and probes. The steady state condition must be working surfaces (including standard machine deviation);
achieved.
∆TTotal ≤ 10 (≤ ∅ 355 mm) up to ≤ 20 °C (≥ ∅ 800 mm)2) (dia-
– A test weld and at least one test idle cycle specimen for larger meter-dependent)
components.
– Plane-parallelism of the heated plate – split heated plates
3.1.3 Work and workplace correspondingly dimensionally stable and firmly mounted; per-
missible deviation from plane-parallelism within the effective
The working sequence and execution must ensure: surface area in accordance with table 2.
– A self-contained, clean working area with no interference from – Reliably-operating control/regulatory facilities for the appli-
other working areas, draughts or invasion by dust, dirt, cation of reproducible welding parameters within the limits of
moisture or the like; permissible application.
– The provision of clean, undeformed workpieces. If prefabri-
– A data recording facility displaying the pressure-(path)-time
cation takes place outside the welding area, internal and exter-
graph is advantageous
nal temperature differences must not differ by more than
approximately ∆T ≤ 5 °C from each other and the workplace;
Table 2. Permissible deviations from plane parallelism of the heated
– Cleaning processes only with grease-free cleaners and plates, including split elements, within the effective surface
sufficient ventilation time. The cleaning processes or surface area.
machining of the joint faces must be repeated at the welding
site, if necessary, in the case of prefabricated segments and Permissible deviation from Nominal external casing pipe
joint faces. plane parallelism diameter
The requirements of DVS 2207-5, paragraph 5, must be fulfilled. [mm] [mm]

3.2 Heated plate welding ≤ 0.4 ≤ 355

3.2.1 Equipment requirements ≤ 0.5 400 ≤ 560

The machines and equipment used must guarantee a safe,
reproducible process with sufficiently constant welding
parameters, c.f. DVS 2208-1. This requires:
– Secure clamping (fixing and aligning) and control of the work
with even transmission of compressive forces over the entire
welding surface/circumference of the pipe (a); diameter-
dependent admissible gap widths by bending up and
machining deviations from plane-parallelism in accordance
with table 1; see also DVS 2208-1, paragraph 4.1.2;
– Adapted jigs enveloping the pipe, which do not cause any
inadmissible embossing/notching of its surface;
– Chucking/clamping of the work close to the welding plane, with
appropriately-shaped jigs in the case of segmental mitred
welds;
≤ 0.8 630 ≤ 800
≤ 1.2 > 800
3.2.2 Preparation of the welded material/joint sub-faces
The following points must be checked for workpieces clamped
into the machine before the welding process commences:
– Alignment of the joint sub-faces with minimal offset, so that the
requirements for the finished weld can be guaranteed;
– Sufficient contact of the welding surfaces around the entire
circumference of the pipe must be ensured. If necessary, the
prefabricated workpieces must be machined while clamped
into the machine (by a plane integral to the machine). The
permissible gap width/deviation from plane parallelism must

1) Clamped pipe ends, carefully machined flat, are used for measurement. Two reference specimens (spacers) are placed on the axis of the pipe parallel
to the plane of the guide/power spar and the pipe ends brought into contact with each other at the joint pressure applicable to the pipe. The difference
in gap widths measured, unpressurised and under joint pressure, must not exceed a tolerance range of 0.25 mm.
2) Measured in the working position in a draught-free environment with the heated plate temperature set at 210°C

392

satisfy the requirements of table 1, point (b) of this Supple-
ment.
– The cleanliness of the welding (workpiece) faces must be
verified (see also paragraph 3.1.3).
3.2.3 Welding process
R&D INTAKE MANIFOLDS
The heated plate welding process and guide settings for the
process parameters are described in DVS 2207-1. The
parameters specified for execution of the process (heated plate
temperature, pressure and time increments) must be observed.
The heating plate temperature range is between 200 and 220 °C.
Notes on the process stages shown in diagrammatic form in
Fig. 1:
– Alignment:
Initial fusion of the welding surfaces until the parts to be
welded are in full contact with the heated plate (small molten
bead) around the entire circumference (inside and out).
The alignment time (tAG) emerges from the necessary depth of
burn-off.
Alignment pressure = joining pressure: pAG ≈ 0.15 N/mm2
– Heating-up/melting process:
The depth of fusion of the joints required for welding is created
at reduced pressure (fixing pressure only).
Guideline for tAS – dependent on wall thickness – in accor-
dance with working instruction or DVS 2207-1.
Heating-up pressure pAW ≈ 0.01 N/mm2
– Change-over time (tU):
The time between lifting off the heated plate and the welding
faces encountering each other for joining/welding must be kept
as short as possible.
Guide settings under working instruction or DVS 2207-1.
(The change-over time should be ≥ tU 5 ≤ 8 seconds,
depending upon the thickness of the wall, where pipe wall
thicknesses are 3 – 15 mm.
– Jointing
The joining pressure (pF) is established quickly with bead
formation during the joining period (tF).
tF approximately 5 to 15 seconds – depending upon the wall
thickness.
The cooling time (tK) for the joint/cross-section of the weld
follows, maintaining the joining pressure (pF) up to approxi-
mately ≤ 70 °C.
Guide settings for tK and pF in accordance with working
instruction or DVS 2207-1.
Mechanical stresses on the welded joint must be precluded
until it has cooled close to the temperature of the pipe.
3.3 Hot gas extrusion welding
Hot gas extrusion welding is described in Directives DVS 2207-4
and its Supplement (parameters) and DVS 2207-5. The major
requirements and specifications are set out below, in conjunction
with DVS 2207-5, paragraph 5.2.
As well as process variant II (in accordance with DVS 2209),
applied predominantly to longitudinal and circumferential welds
on PE casing pipes, variant I, the intermittent process, is used.
Experience has shown that the greater demands of long-term
strength (welding factor “fs”) are not achieved by process variant I
due to manual execution with separate functions and the
observance of parameters which can be influenced to a high
degree by the welder, unlike the mechanised and partially
mechanised process variants in accordance with DVS 2207-5,
table 4; see DVS 2207-4, paragraph 17.
Page 3 to DVS 2207-5 Supplement 1
“Intermittent” variant I is used for T-pieces with mounted
discharge pipes and for special forms of weld when producing
fittings from PE casing pipes. In particular, it is used if the face
geometry charges in the course of the weld, which cannot be
accomplished reliably using the invariable welding shoe shapes
of “continuous” process variant II.
Alignment pressure Joint pressure
Pressure
Heating-up pressure
Alignment Joining
time Heating-up time time Cooling time Time
Change-over time
Figure 1. Diagrammatic representation of stages in the process of
heated plate welding (based on DVS 2207-1).
3.3.1 Equipment requirements
The equipment used must guarantee even preheating (initial
fusion) of the joint faces and continuous feed of the
homogenously plasticised welding filler into the welding groove
(V- or fillet weld) with the exercise of sufficient welding pressure
through the welding shoe/the workpiece to be welded on to the
welding deposit. This principally requires the following:
– Adjustment/alignment of the hot gas jet to the shape and path
of the weld;
– A simple welding unit readjustment facility for the enclose
support of the welding shoe (tool) on the circumference of the
pipe and centred longitudinal guidance across the path of the
weld;
– Appropriate shaping and a welding shoe adapted to the
dimensions of the weld (width of joint coverage, weld camber,
contact length, the front “shoe tip” closing the joint, edge
rounding and recessing), in accordance with the process
directive and working instructions;
– PTFE or equivalent plunger for suitable shaping (weld shape
and width) for manual pressure on the weld deposit at the
ends, etc. and for intermittent execution of the process.
3.3.2 Preparation of the parts to be welded/joint sub-faces
– The specific welding parameters of PE moulding material must
match. The melt flow rate (MFR 190/5) of the workpieces and
the fillers must not deviate from each other by more than
0.5g/10 minutes under DIN EN 253. Control measurements
must be taken if necessary.
– The surfaces to be welded (joint faces and surface areas in the
vicinity of the edges of the joint) must be machined; see also
DVS 2207-5, paragraph 5.
– Secure anchorage of the workpiece and maintenance of the
joint shape and root gap specific to the process in accordance
with working instructions and process directive DVS 2207-4
must be guaranteed. If necessary, tack welds or a WZ root
pass in the intermittent process must be provided.
– The cleanliness of the welding surfaces and the welding filler
material must be verified, see also section 3.1.3.
3.3.3 Welding process
Continuous observance of the parameters of face/welding
deposit temperature, welding pressure on the welding deposit
and an appropriate welding speed must be ensured. This
requires:
– Controlled, safe tool guidance;
– Penetration tests on the joint faces in the entire weld face im-
mediately in front of the welding tool. Necessary depth of
fusion ≥ 0.5 mm.
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– Continuous observation of the weld site and any necessary
readjustment of the welding unit (centring and bearing on the
pipe) and adjustment of the advance control system.
– Subsequent manual pressing of the welding deposit into the
R&D INTAKE MANIFOLDS
ends of the weld and other problem areas with the welding
tool, and with the hand plunger in insufficiently accessible ar-
eas.
– In the intermittent process, face heating must be undertaken
carefully and inspected (penetration tests). The welding filler
material must be introduced directly into the welding area and
pressed in and down with the plunger for a sufficient period.
– Remachining the edges of the weld (removing weld flashes),
without damaging the surfaces of the pipe and with minimal
scraping depths of ≤ 0.1 x s, but ≤ 1 mm.
Working instructions and process directives must be observed.
3.4 Hot gas string-bead welding
The process is described in Directive DVS 2207-3. In general,
only lower long-term weld strengths are achieved in the hot gas
welding process with the introduction of welding filler, e.g. hot
gas string-bead welding with a welding rod, than in the process
described above. This is all the more applicable if the welding
has to be carried out under difficult conditions, e.g. on site and in
trenches.
For these reasons, hot gas welding should not be used for PE
casing pipes or the production of fittings, or only used under
exceptional circumstances. Should this process nevertheless be
integrated into production, e.g. for root passes or in inaccessible
joint face positions, the requirements of DVS 2207-3 must be
fulfilled.
4 Testing welded joints
The tests described below may be used to test welded joints,
taking account of the existing requirements. A decision on the
applicability and informative content of individual test procedures
or combinations thereof must be made on the basis of the
circumstances of each individual case.
Reference is made to Directive DVS 2207-5, paragraph 6, in
respect of the informative content of individual test procedures.
4.1 Non-destructive test methods – Visual inspection
In general, visual inspection is the only non-destructive test
applied to PE casing pipes. All welded joints are inspected for
visible errors in execution and external indications of internal
defects in execution.
Radiographs and ultrasound tests are not customary within the
scope of this Directive. Should such test processes be used for
corresponding welding processes, weld shapes and weld
dimensions under exceptional circumstances, Directive DVS
2206 must be consulted.
394
4.2 Destructive test methods
4.2.1 Tensile test
The tensile test is carried out in accordance with paragraph 6.1 of
Directive DVS 2207-5.
Note on table 1 of Directive 2207-5:
If the dimensions of the test specimen cannot be maintained for
design reasons, smaller dimensions (specimen length) may be
selected, provided that the remaining specifications are fulfilled.
An appropriate conversion of machine speed to the same
specimen deformation speed must be made (c.f. Fig. 2).
External mitre
Abutment plane
(upper edge)
Internal
mitre
Figure 3. Location for sampling from segmented elbows
a) Specimen from the abutment plane for the tensile test
b) Specimen from the internal and external mitre for the
technological bend test.
In the case of segmental prefabricated fittings, particularly those
with a large diameter, one (or, if necessary, two) test specimens
with reasonable leg coils may be taken from the abutment area
and on the diagonal of the weld to the axis of the specimen, c.f.
Fig. 3.
4.2.2 Technological bend test
The technological bend test is conducted in accordance with
paragraph 6.2 of Directive DVS 2207-5. The dimensions of the
specimen must be selected in accordance with table 2 therein.
When testing specimens from the outer or inner mitre of a
segmental elbow (see Fig. 2), the excess of deformation angle
“α” achieved in the test above the existing angle of the specimen
“β” must be regarded as the result.
In the case of mounted discharge pipe T-pieces with a fillet weld,
specimens are taken, tested and analysed in accordance with
Fig. 3.
4.2.3 Tensile creep test
The tensile creep test is implemented and evaluated in
accordance with paragraph 6.4 of Directive 2207-5. The
specimen geometry is identical to that in the tensile test.
The component strength of fittings may also be verified in an
internal pressure creep test in water, analogous to the
stipulations in DIN 16963-5. Apertures in fittings must then be
L fKurz
V Kurz = V Normal × ----------------------
L fNormal
LfNormal = Specimen length in accordance with DVS 2203-2,
table 1
LfKurz = Shortened specimen length
VNormal = Machine feed for specimen length Lf;
Guide setting for PE-HD under DVS 2203-2, table 3
= 50 mm/min
VKurz = Machine speed for shortened specimen length
Figure 2. Example of a shortened specimen from a prefabricated fitting.
 Page 5 to DVS 2207-5 Supplement 1

closed so that the resultant longitudinal and lateral forces are 5.1.2 Indications of good WE welded joints
completely removed from the fitting itself. A good WE welded joint displays the following crucial formation
characteristics (Fig. 5):
4.3 Imperviousness test

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An imperviousness test must be carried out using compressed air
at approximately 0.2 to 0.3 bar. No leaks (bubbles) must be
visible one minute after coating the welds with a harmless
foaming aqueous solution (e.g. a modern biodegradable
domestic washing-up liquid in the lowest possible concentration).
Should there be any doubt or dispute, the pressure must be
maintained for ≥ 10 minutes. Figure 5. Extrusion weld with well-formed cap and good root penetration
(in accordance with DVS 2206).

5 Requirements imposed on welded joints – Even weld camber running centrally to the joint, joint edge cov-
erage by V-weld ≥ 2 mm (3 ± 1 mm)
The requirements imposed on welded pipe joints in paragraph 7
– Smooth weld form, reflecting the shape of the welding shoe,
of Directive DVS 2207-5 apply to fittings.
with the weld surface not showing any signs of disintegration,
The requirements for welded joints to be inspected in accordance overheating, rising bubbles, inhomogeneity, inclusions, etc.
with paragraph 4 of this Supplement are set out below.
– Minimal face offset.
5.1 Visual inspection – Notch-free, penetrative weld root with slight root sag; root con-
cavity and lack of fusion at the edges of the weld (notches with
The subjects of visual inspection are:
sharp edges) are serious faults in production.
– Maintenance of the process-specific weld formation, particu-
– Weld edge machining depth ≤ 10% of the pipe wall thickness
larly in respect of the weld shape, dimensions, geometry and
and ≤ 1 mm
symmetry;
– Inspection of the surface characteristics for any damage to the 5.1.3 Indications of good WZ welded joints
surface of the pipe in the vicinity of the weld as a consequence A good WZ welded joint has the following particular features
of the handling of the fittings, clamping, the effects of tempe- (Fig 6):
rature etc. during implementation of the process.
Welds (face shape, bead/weld formation, presence of blowholes,
large pores, accumulations of pores, root and edge notches, root
suck-backs and lack of side wall fusion in weld cross-sections)
are assessed in accordance with evaluation group 2 in DVS
2202-1. Should deviations from the requirements occur in
individual cases, they must be specified in advance.
Increased face offset limits of ∆s ≤ 0.2 s (s = thickness of the
thinner wall) are accepted for PE casing pipe fittings at the
relatively low wall thickness usual within the scope compared to
the pipe diameters on one hand and the difficult production
conditions of some structural forms with internal medium pipes
on the other, such as outward necked T-pieces in heated plate
welding. Under particularly difficult conditions for fittings – e.g.
the outward-necked T-piece – up to ∆s ≤ 0.3 s is admissible, if
the associated greater weakness is observed in static testing.

5.1.1 Indications of good HS welded joints

Crucial features of good HS welded joints on visual inspection
are (Fig. 4):
Figure 6. Hot-gas welded butt joint with diagram of welding filler
principle
a) Well-filled weld without backing run (weld structure e.g.
one ∅ = 3 mm + one ∅ = 4 mm + twice ∅ = 4 mm)
b) Weld with inadmissible root gap notches – non-penetrative
root.

– Even, slightly reinforced cap with straight passes;

– Flat transitions between the individual passes and continuous
joint edge coverage;
– Process-specific double bead on both sides, each pass without
Figure 4. Good bead formation in heated plate welding. indications of burning
– Minimal face offset
– Even formation of a double bead throughout the entire length
of the weld/circumference of the pipe (inside and outside); – Notch-free weld penetration with slight sag. Root suck-back is
inadmissible.
– Individual beads as symmetrical as possible, rounded shape,
not pressed into a peak by excessive joint pressure; – Similarly evident “heat delustering” on both sides of the weld
as an indication of the even application of heat.
– Root of the central groove outside the cross-section of the
pipe, double bead width in the approximate vicinity of the pipe 5.2 Requirements for the tensile test
wall;
The requirements of Directive DVS 2207-5, paragraph 7.2 and
– Minimum face offset. table 3, apply.

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Page 6 to DVS 2207-5 Supplement 1
5.3 Requirements for the technological bend test
The requirements of Directive DVS 2207-5, paragraph 7.2 and
Fig. 14, apply.
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5.4 Requirements for the tensile creep test
The requirements of Directive DVS 2207-5, paragraph 7.3 and
table 4, apply, with the exception of the footnote.
5.5 Requirements for the imperviousness test
The independent impervious test on factory mass-produced
fittings may be waived, if the following requirements are fulfilled:
– Use of certifiably qualified, quality-assured semi-finished prod-
ucts and similarly certificated welding fillers, if applicable;
– Certified welding process with qualified, regularly-serviced
welding tools;
– Use of qualified, certified welders under DVS 2212-1 and –2,
under similarly qualified, certified supervision (e.g. under DVS
2213 and 2214);
– Compliance with test certificates under Directive DVS 2207-5,
table A 5-2, pos. 1 to 5.
In the case of individual production, particularly the production of
fittings or valve jacket casings on site, they must be subjected to
an imperviousness test at excess air pressure in accordance with
paragraph 4.3, after installation in the pipe system and prior to
filling with foam: see also Directive DVS 2207-5, paragraph 6.5.
No leaks, atypical deformation or other inadmissible changes
may take place.
6 Quality assurance
Directive DVS 2207-5, paragraph 6, must be applied analogously
to quality assurance.
This particularly affects the following, if possible on the basis of
an ISO 9000 ff. quality assurance/quality management system:
– Effective quality assurance measures for the factory produc-
tion of casing pipe fittings within the scope of factory produc-
tion;
– The use of approved, regularly-maintained machines and
equipment subjected to certified regular operating tests
– The use of qualified welders with examination certificates in
the welding process used under DVS 2212-1 and –2, under
qualified supervision (e.g. under DVS 2213 and DVS2214);
– Specimen tests after machine setting and at regular inter-
vals during production under DVS 2207-5, Annex 5, table A
5-2.
– Final testing/visual inspection of all the welded fittings.
– Quality certification of semi-finished products and welding filler
materials
– Documentation of certificates and test results for welding work.
396
7 Standards and directives
DIN EN 253 Preinsulated bonded pipe systems for directly
burried hot water networks – Pipe assembly for
steel service pipe, polyurethane thermal insulation
and outer casing of polyethylen.
DIN EN 448 Preinsulated bonded pipe systems for directly
burried hot water networks – Fitting assemblies for
steel service pipes, polyurethane thermal insulation
and outer casing of polyethylene.
DIN EN 488 Preinsulated bonded pipe systems for directly
burried hot water networks – Steel valve assembly
for steel service pipes, polyurethane thermal
insulation and outer casing of polyurethane.
DIN 8075 Polyethylene (PE) pipes – PE 63, PE 80, PE 100,
PE-HD – General quality requirements, testing
DIN 16776-1 Polyethylene (PE) moulding components,
classification and description
DIN 16963-5 Pipe joints and components of polyethylene (PE)
for pipes under pressure, PE 80 and PE 100 – Part
5: General quality requirements, testing
DVS 2202-1 Imperfections in thermoplastic welding joints –
Features, description, evaluations
DVS 2203-1 Testing of welded joints of thermoplastics – Test
methods, requirements
DVS 2203-2 Testing of welded joints of thermoplastics – Tensile
test
DVS 2203-4 Testing of welded joints of thermoplastics plates
and tubes – Tensile creep test
DVS 2203-5 Testing of welded joints of thermoplastics plates
and tubes – Technological bend test
DVS 2206 Testing of components and constructions made of
thermoplastic materials
DVS 2207-1 Welding of thermoplastics, Heated tool welding of
pipes, pipeline, components and sheets made from
PE-HD
DVS 2207-3 Hot gas welding of thermoplastic polymers; panels
and pipes
DVS 2207-4 Welding of thermoplastics, Extrusion welding –
panels and pipes
DVS 2207-5 Welding of thermoplastics – Welding of PE casing
pipes – Tubes and tubular components
DVS 2208-1 Welding of thermoplastics – Machines and devices
for the heated tool welding of pipes, pipeline
components and sheets
DVS 2209-1 Welding of thermoplastics – extrusion welding;
procedures, characteristics
DVS 2209-2 Welding of thermoplastics – Hot gas extrusion
welding – Requirements for welding machines and
tools
DVS 2212-1 Examination of plastic welders – Group I – Hot gas
welding with torch separate from filler rod (WF), hot
gas string-bead welding (WZ), heated tool butt
welding (HS)
DVS 2212-2 Examination of plastic welders – Examination
group II – Hot gas extrusion welding (WE)
DVS 2213 Specialist for plastic welding – Examination
DVS 2214 Regulations for the examination of the specialist for
plastic welding